Resolving a serious electrical fault on an Audi A6

Soldato
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I’ve got a bit of a problem with my 2005 C6 generation Audi A6, so I thought I’d post up on here to see if anyone might have experienced something similar with another VAG car.

After more than 40 minutes of driving, the car beeps and the DSC warning light and what I think is a yellow brake warning light appears on the integrated dash display. These then immediately disappear, but the DSC light on the dash itself remains illuminated. The instant this happens, the car exhibits what feels like a serious gearbox fault - the car revs freely but barely moves, it becomes difficult to change gear even with the paddles. Turning the car on and off again has no effect, leaving it to cool down for an hour totally resolves the problem, with all lights no longer illuminated on the dash.

This issue has kind of occurred before in the sense that once or twice, during a long drive, the DSC dash light would illuminate and I would feel a hesitation or shudder in the gearbox. However, after a couple of seconds, it would sort itself out, although the DSC light would stay illuminated. At the time, I put it down to a sensor issue but this recent development where I had to crawl to the next junction at 30MPH would indicate that it’s something more serious.

After researching online, I noticed a couple of people with similar problems reported changing the brake pedal switch solved the issue for them. I put the car into the dealer and mentioned this, but they called me this evening stating that they didn’t think it was anything to do with the switch as it “wasn’t showing a fault code” (personally I was surprised that their diagnostics are that precise, but I know little about such things).

They then admitted that they’re pretty sure there’s nothing wrong with the gearbox either, and that it’s likely to be some sort of connection / wiring issue, which will involve taking the entire car apart to sort out. Understandably, I’m reluctant to let them do this as I’ve already spent over half the value of the car in repairs in the month or so I’ve had it.

Do we think it’s worth changing the brake pedal switch myself to see if it fixes it, considering it’s a cheap part. Is there anything else I should be checking?
 
I'd probably get an independent VCDS scan done on it if possible, but whenever I've seen similar (I assume ESP and ABS light), it's either a wheel speed (ABS) sensor or the ABS module failing.
 
I'd probably get an independent VCDS scan done on it if possible, but whenever I've seen similar (I assume ESP and ABS light), it's either a wheel speed (ABS) sensor or the ABS module failing.

They're the main dealer, and I think I'd struggle to find anyone else with VCDS around here. I could have course buy it myself - I've seen kits available for £50-80, but I doubt I'd be able to interpret what I'm looking at fault-code wise.
 
Put a new brake pedal switch on it if others have had a history of that. The switch wont throw a fault light if its faulty anyway its just an on and off signal and the car wont know you didn't push the pedal. That's a good start, the dealer will just delve in and cost you a lot of money without having a clue where to start looking.

As for VCDS this is an intermittent electrical fault which is why the dealer doesn't have a fix. VCDS will just give you the same codes as they have with no real idea where to start.
 
For your fault I would buy VCDS, you can check if the brake pedal switch is working by monitoring the inputs on the module. You can then check if it is working when the fault is occurring.

VCDS allows real time monitoring of all the sensors that you can log from start up until the fault occurs this can help pinpoint wiring or sensor problems.
 
Is the battery and alternator definitely good? Any sort of voltage drop will send the ABS/DSC mental.

If they’re OK it sounds does sound like the ECU possibly is losing track of the wheel speeds.

The only way you’ll solve the without randomly swapping parts is to capture live data when it happens and work from there.
 
Battery is new, alternator was checked and seems fine. I've ordered a brake switch which is coming from the US, so probably won't be here for another week. In the meantime I think I'm going to keep driving and monitoring it.

Live capturing data on VCDS would involve (I assume) having the cable from the OBD port plugged into my laptop whilst I'm driving along, then pulling over when the fault occurs and looking at the data on the laptop? Is there anything I should be looking out for in particular?
 
Is this Multitronic? My dad had a similar issue on his A6. Had to press a button under the ash tray to temporarily clear the fault.

I believe it was a sensor on the gearbox it's self that was failing but I can't quite remember now.
 
Battery is new, alternator was checked and seems fine. I've ordered a brake switch which is coming from the US, so probably won't be here for another week. In the meantime I think I'm going to keep driving and monitoring it.

Live capturing data on VCDS would involve (I assume) having the cable from the OBD port plugged into my laptop whilst I'm driving along, then pulling over when the fault occurs and looking at the data on the laptop? Is there anything I should be looking out for in particular?

With VCDS you can monitor the individual switch. So you don't need to be driving along. You can just fire up VCDS, get to the right menu, and check the switches individually to see if they are operating. If it's an intermittent problem, you can just drive along until it happens, and when it does, if you are safe to do so, you can pull over, then connect up, and monitor it then, preferably without turning the car off. You wont NEED it plugged in and working during the whole drive.

You can have a look at this page to see where to look when using VCDS to check individual switches:

http://wiki.ross-tech.com/wiki/index.php/Checking_Cruise_Control_using_Measuring_Values

It does say it's for checking cruise control, but cruise wont work if the switches don't work, so it's showing how to check the switch.
 
Is this Multitronic? My dad had a similar issue on his A6. Had to press a button under the ash tray to temporarily clear the fault.

I believe it was a sensor on the gearbox it's self that was failing but I can't quite remember now.

Yes, it's multitronic. I assumed that the button under the ash tray was only used for when the car was stuck in park? That isn't the issue here.

@xs2man thanks for that info, I'm still deciding what to do with the car assuming the switch replacement doesn't work, but if I get VCDS I'll be sure to do that.
 
So, I’ve been driving it around whilst waiting for the new switch to arrive, and have been monitoring the issue.

Tonight, it did the following:

Performed totally normally for around 30 minutes. Then ESP light comes on, car comes out of gear, then sorts itself out. A couple more slight hiccups in the next 10 minutes, but nothing major.

Then, the yellow handbrake malfunction light in the dash screen comes on for a second, and the car comes out of gear again. This only lasts for a second or 2, then the light goes off and the car is fine. Throughout the next 30 minutes this happened every 3-5 minutes, with the car briefly coming out of gear each time the handbrake malfunction light came on, then coming back into gear when the light went off after a couple of seconds.

This sounds more like an electrical issue than a gearbox fault to me, what do we think?
 
Might be a daft question but how much brake fluid is in your brake reservoir? If that's low it can bring on the brake fault light.
 
Gearbox solenoid as a worst case? Only way to be sure is to check with vcds like others have mentioned.
 
Gearbox solenoid as a worst case? Only way to be sure is to check with vcds like others have mentioned.

Yeah, if the switch doesn’t fix it I’ll probably do that.

Might be a daft question but how much brake fluid is in your brake reservoir? If that's low it can bring on the brake fault light.

I’d have thought that would activate the brake fault light and not the parking brake fault light? As far as I know it’s a different system
 
I’d have thought that would activate the brake fault light and not the parking brake fault light? As far as I know it’s a different system

Ahh, didn't realise the A6 had an electronic handbrake. I did say it might be a daft question :o
 
Gearbox speed sensor losing speed signal I'm going to say. Car will still see it moving via the wheel speed sensors and gearbox will see no speed intermittently and keep dropping gears. Problem your having is if the sensor hasnt actually failed fully and is just giving incorrect readings you will never get a fault code for it
 
Gearbox speed sensor losing speed signal I'm going to say. Car will still see it moving via the wheel speed sensors and gearbox will see no speed intermittently and keep dropping gears. Problem your having is if the sensor hasnt actually failed fully and is just giving incorrect readings you will never get a fault code for it
Sounds plausible. Another point, as someone has mentioned previously, could be a wheel speed sensor starting to go faulty. Completely different car, but my Civic had an intermittent ABS and VSA fault for several weeks before a speed sensor failed on me. Could be a similar story here? Another easy thing to check with a diagnostic unit too - just leave it plugged in and monitoring whilst driving and take a glance when it happens.
 
So, I finally bought VCDS and got it hooked up. In the last few weeks it's mostly been behaving itself - the parking brake fault light is now permanently illuminated and will not disappear even when the code is cleared in VCDS, but apart from the occasional cutting out for a second or two the car has been OK.

A couple of days ago, it cut out again, the red battery warning light came on the dash and the power steering stopped functioning. I coasted to a parking space, turned the car on and off again and it was fine. The battery is new.

I read the codes today, there were a vast number for all kinds of different things - mostly old stuff that I don't think has anything to do with my problem. These are the ones that I think are the most pertinent:



01315 - Gearbox control unit

004 - no signal/communication - sporadic

Ambient conditions:

Error status: 00100100

Error priority: 2

Error frequency: 7

Distributor counter: 111

Mileage: 108988 km

Time specification: 0

Date: 2018.01.29

Time: 18:49:52


00473 - Control unit for electric parking brake/hand brake (J540)

008 - implausible signal

Ambient conditions:

Error status: 01101000

Error priority: 3

Error frequency: 1

Distributor counter: 75

Mileage: 109258 km

Time specification: 0

Date: 2018.02.07

Time: 15:09:47


00263 - Gearbox

004 - no signal/communication - sporadic

Ambient conditions:

Error status: 00100100

Error priority: 2

Error frequency: 35

Distributor counter: 98

Mileage: 108894 km

Time specification: 0

Date: 2018.01.24

Time: 19:18:10


01315 - Gearbox control unit

004 - no signal/communication - sporadic

Ambient conditions:

Error status: 00100100

Error priority: 2

Frequency of errors: 36

Distributor counter: 98

Mileage: 108894 km

Time specification: 0

Date: 2018.01.24

Time: 19:18:11


01312 - Data bus drive

014 - defective - sporadic

Ambient conditions:

Error status: 00101110

Error priority: 1

Error frequency: 14

Distributor counter: 111

Mileage: 108959 km

Time specification: 0

Date: 2018.01.25

Time: 19:39:19


00384 - Optical data bus

011 - Interruption - Sporadic

Ambient conditions:

Error status: 00101011

Error priority: 5

Error frequency: 1

Distributor counter: 112

Mileage: 109851 km

Time specification: 0

Date: 2018.02.20

Time: 17:11:32


01314 - Engine control unit

004 - no signal/communication - sporadic

Ambient conditions:

Error status: 00100100

Error priority: 3

Error frequency: 119

Distributor counter: 113

Mileage: 108959 km

Time specification: 0

Date: 2018.01.25

Time: 19:39:25



01316 - Brake control unit

004 - no signal/communication - sporadic

Ambient conditions:

Error status: 00100100

Error priority: 3

Error frequency: 17

Distributor counter: 86

Mileage: 108961 km

Time specification: 0

Date: 2018.01.25

Time: 19:41:54




02432 - Parking motor left Power supply (V282)

011 - Interruption - Warning light ON

Ambient conditions:

Error status: 11101011

Error priority: 2

Error frequency: 79

Distributor counter: 56

Mileage: 109256 km

Time specification: 0

Date: 2018.02.07

Time: 15:09:45


Ambient conditions:

Voltage: 11.80 V

Quantity: 116

In my limited knowledge, this points to a fault with the gearbox ECU which is then causing other faults in other modules such as the ESP and parking brake module. However, when I tried to clear the parking brake fault in VCDS, the car beeped at me and several lights flashed up on the dash, including the ESP, ABS and red park brake indicator. The other thing which makes me doubt this slightly is the fault I had a couple of days ago with the battery light and power steering, which to me would suggest an alternator issue. This is the only time it's happened however, and it could be totally unrelated.

So, any ideas? I suspect I may be asking a bit much here as this seems to be fairly specialist stuff. I certainly can't find anyone here (including the Audi dealer) who seems to be able to give me a reliable diagnosis.
 
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