2015 Audi Q5 Suspension

Rear subframe rusted out at only 85,000 miles

2015 Audi Q5 Quattro (all wheel drive). During recent inspection the vehicle was found to have extreme corrosion, cracking, and structural failure of the rear subframe and subframe crossmember. The rear steel subframe is manufactured as an assembly. The rear subframe assembly supports all of the rear suspension components and rear drivetrain and drivetrain components. My vehicle is always garaged and no other corrosion was found during inspection of the entire vehicle. The finding is a manufacturing defect that is only isolated to the rear subframe assembly of the vehicle. Due to the extreme nature of corrosion and cracking found on the subframe assembly this should be considered a high priority warning for Audi Q5 owners. A total failure of all rear suspension and drivetrain components may result.

To Whom It May Concern, I am writing to formally report a serious safety issue involving my 2015 Audi Q5 TDI (VIN # [XXX] ), which has developed severe corrosion on the rear subframe. I am the original owner of this vehicle, which has 92,700 miles and has been garage-kept and exclusively serviced by authorized Audi dealerships since purchase. On [XXX], following a failed Virginia State safety inspection, the vehicle was inspected by Audi of Chantilly, VA. Their service department confirmed that the rear subframe is cracked due to extensive rust and recommended immediate repair. I have attached both the inspection report and supporting photographs. This is not an isolated case. Numerous Audi Q5 owners have documented similar corrosion on the rear subframe, often attributed to a plastic cover that traps moisture and accelerates rusting. This appears to be a design defect with potentially dangerous implications. As it stands, the vehicle is not drivable. The compromised subframe poses a serious risk of structural failure while in motion, increasing the potential for loss of control, a crash, or injury. The dealership has estimated repairs at over $9,000, which I am currently seeking coverage for through Audi Customer Service. However, Audi has indicated that their corrosion warranty covers only body panels—not subframe components—despite the fact that the defect stems from their design. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Audi Dealer inspection report said severe rear sub frame rust is a safety issue and requires replacement

The Audi Q5 was new in 2015 and I am the original owner. The vehicle has 135,600 miles on it. During an oil change visit to my repair shop, they informed me of significant rust corrosion to the subframe. My Audi dealer in Chantilly acknowledged that subframe rust was a design flaw on model years 2014, 2015, and 2016. Audi will not cover this under their 12 Year Rust Corrosion Perforation warranty. I believe this to be a significant safety hazard to the owners and their families who are still driving their Q5 without knowledge of the impending disaster. Impending disaster could be a subframe collapse at highway speed.

MY 2015 AUDI Q5 HAS 36,000 MILES ON IT, IS GARAGE KEPT AND TAKEN WELL CARE OF. IT JUST NOW HAD BOTH REAR BEARINGS GO OUT AT THE SAME TIME. IT MADE A HORRIBLE NOISE WHILE ON SMOOTH HIGHWAY, AND I HAD IT TOWED TO A MECHANIC WHO DEEMED IT UNSAFE TO DRIVE. THERE IS A RECALL ON THE FRONT BEARINGS BUT AUDI REFUSES TO TAKE RESPONSIBILITY FOR THE ISSUE. UNSAFE AND COULD KILL PEOPLE.

TL* THE CONTACT OWNS A 2015 AUDI Q5. THE CONTACT STATED THAT THERE WAS AN ABNORMALLY LOUD SOUND COMING FROM THE VEHICLE WHILE DRIVING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE DRIVER AND PASSENGER SIDE WHEEL BEARINGS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 90,000.