audiman94

Anyone have Removal/Replacement instructions for the ignition switch in a 1994 90s?

white90+hibredS4

STFA

MikTip

Recall
Circular Code: KB
April 1996
Subject: 1994-96 Model Audi Vehicles
Ignition Switch Replacement
Dear Audi Dealer:
This is to inform you of the initiation of a voluntary safety recall campaign for some 1994-96 model
Audi vehicles. This recall pertains to the replacement of the ignition switch in affected vehicles.
Defect
Description
Audi has found that some of the ignition switches in affected vehicles may have been
improperly manufactured and could cause electrical accessories to malfunction when
the engine is started.
Vehicle
Identification
Number Ranges 1994/95 Audi 90
WAU_ _88C_RA113204 -WAU_ _88C_SA083727
1994-96 Cabriolet
WAU_ _ _8G_RA004048 -WAU_ _ _8G_TA004996
1994-96 Audi 100, A6, S4, S6
WAU_ _ _4A_RN044081 -WAU_ _ _4A_TN038487
Please note that the above VINs represent the lowest and highest serial numbers
of affected vehicles. Use of the V-Crest campaign inquiry system will allow you to
determine whether or not a particular vehicle, within the above VIN ranges, requires the
corrective work.
recall repair work or a repair outside the VIN range.
NOTE: Audi of America, Inc. will not reimburse under this recall action any duplicate
Model
Numbers
1994/95 Audi 90 1994-96 Cabriolet 1994-96 Audi 100, A6, S4, S6
8C24_ _ ; 8C25_ _ 8G74Y8 4A23_ _ ; 4A53_ _ ; 4A25_ _
Important: Please Provide A Copy To All Personnel With Recall-Related Responsibilities !
Audi of America, Inc.

2/12
Remedial
Action
Each affected vehicle requires the replacement of the ignition switch.
Owner
Notification
Mailing
Audi of America, Inc. will mail first class notification letters to all known owners of
affected vehicles, beginning on or about April 29, 1996. A copy of the owner letter is
included in this circular.
Vehicle
Allocation
Enclosed with this package is a computer list containing information for vehicles and
owners located within your area of responsibility.
IMPORTANT NOTE:
The above-mentioned listing includes owner names and addresses obtained from state motor vehicle registrations.
Under the law of some states, including regulations set forth by the California Department of Motor Vehicles, vehicle
registration information may only be used for recall purposes. Use for other reasons may constitute a violation of
state law.
Limitations on Sale or Lease of Certain Vehicles
Section 154(d) of the National Traffic and Motor Vehicle Safety Act of 1966 mandates that dealers
correct, prior to delivery for sale or lease, any vehicle which fails to comply with an applicable Federal
Motor Vehicle Safety Standard or which contains a defect relating to motor vehicle safety. It is,
therefore, imperative that any vehicle in your new or used car inventory and affected by this recall is
corrected prior to sale.
Work
Procedure
Replace Steering Lock/Ignition Switch
WARNING: Always observe all air bag system safety precautions.
This is a general procedure. Minor variations are possible.
-Secure radio code.
-Disconnect battery ground strap.
-Remove left side kneebar
Up to and including 1995 model year, disconnect air
bag voltage supply connector located on passenger
side (arrow).
-Bring wheels into straight ahead position.
3/12

Disconnect air bag unit at left and right side of
steering wheel using Torx T30H tool (Snap-On FTX
30A or equivalent).
Tilt air bag unit.
-Remove air bag unit connector safety clamp
(arrows A & B), if equipped.
-Remove air bag unit.
(Unit must be stored padded side up.)
Pivot steering column "length adjustment" lever
-A-down; use small screwdriver and remove
securing spring clip -B-(where applicable).
-Remove adjustment lever.
Loosen socket-head bolt.
-Remove tilt adjustment lever (where applicable).
4/12

(Only where applicable) remove steering column
trim screws - arrows-.
-Remove upper steering column trim.
Disconnect air bag unit connector -arrow-.
-Place steering wheel in straight ahead position.
-Mark steering wheel/shaft position.
-Remove steering wheel nut and remove steering
wheel.
Use a 4mm hex wrench and loosen hexagonal screw,
either lower or upper trim, as applicable (DO NOT
scratch trim cover).
-Disconnect steering column switch connectors.
-Remove upper trim.
-Remove steering column switch together with lower
trim.
-Unclip housing from instrument panel and remove.
Remove trim screws -2-.
Remove trim molding -1-.
5/12

Remove instrument cluster mounting screws -arrows-.
-Carefully pull instrument cluster from instrument
panel.
-Disconnect electrical connectors and remove
instrument cluster.
Disconnect harness connector from ignition switch.
-Remove shift lock bowden cable cover.
Disconnect cable after prying off mounting clips,
using a screwdriver.
CAUTION: Do not bend cable when disconnecting.
Loosen ignition lock Torx (T30H) screw -arrow-.
6/12

Remove steering column mounting bolts-arrow-.
-Push steering column down and back until
steering/ignition lock housing can be removed.
-Take steering/ignition lock housing to workbench.
-Remove cover sleeve from lock housing.
Use supplied step-drill and drill 3 mm hole 1.5 mm
(0.06 in.) deep into lock housing, as shown.
o 9 mm -0.35 in.
o 0.47 in.
Housing is only 2 mm (0.08 in.) thick.
Excessive drilling will cause lock
cylinder damage.
12 mm -
CAUTION: To avoid drilling too deep into the
housing, DO NOT use a regular drill.
Push retaining spring down through hole
-arrow A-using a punch or similar tool.
-With ignition key in lock cylinder and key in "OFF"
position, pull lock cylinder from ignition lock housing.
Reinstallation
-Use new steering/ignition lock housing for replacement as
follows:
o Audi 90, Cabriolet 8A0 905 851A
o 1994 Audi 100, S4 4A0 905 851L
o 1995/96 Audi A6, S6 4A0 905 851J
7/12

Reuse lock cylinder and with ignition key in "OFF"
position -curved arrow-slide in direction of straight
arrows, until retaining spring locks in place.
-Reinstall lock housing cover sleeve.
-Reinstall all parts in reverse order. Use instructions,
parts and specifications listed below:
NOTE: Ensure proper cable adjustment.
-Use new steering mounting bolt lock nuts, part
numbers:
(2) N 011 184 9 - 8mm
(1) N 902 867 01 - 6mm
o steering column mounting bolts (8mm only):
35 NM (26ft lb)
o ignition lock Torx screw:
7 NM (62 in lb)
o steering wheel nut:
40 NM (30 ft lb)
o air bag unit:
6 NM (53 in lb)
-After reinstallation of all components,
reconnect battery.
-Start engine.
-Check function of all electrical accessories.
-Reprogram radio code.
-Check 1551 functions.
Special
Tool
A step-drill is required to perform this recall. Dealers will receive one (1) drill, free of
charge, either with this package or separately, prior to owner notification.
8/12
Parts
Information

We will automatically ship to you an initial supply of steering/ignition switches and
necessary lock nuts. Additional required switches and lock nuts must be ordered by
you from your facing parts depot. The parts necessary for the recall are:
Quantity Description Part Number Application
1 Ignition Switch 8A0 905 851A Audi 90, Cabriolet
1 Ignition Switch 4A0 905 851L 1994 Audi 100, S4
1 Ignition Switch 4A0 905 851J 1995/96 Audi A6, S6
2 Lock Nut N 011 184 9 All
1 Lock Nut N 902 867 01 All
Please refrain from over-ordering any of these ignition switches; you may be required
to return excess inventory.
Replacement Time/
Reimbursement
It is important to note that recall claims will only be paid for the specific work
performed, as listed below. To ensure proper payment, be sure to use the correct
reimbursement code applicable to the specific vehicle model/model year.
KB Data Entry Procedure
DAMAGE TIME
CODE UNITS WORK SCOPE
(Audi 90)
o Replace ignition switch; wash/vacuum vehicle; provide loaner, if necessary
KB12 245 T.U. 1 Switch 8A0 905 851A
2 Nut N 011 184 9
1 Nut N 902 867 01
(Cabriolet)
o Replace ignition switch; wash/vacuum vehicle; provide loaner, if necessary
KB13 245 T.U. 1 Switch 8A0 905 851A
2 Nut N 011 184 9
1 Nut N 902 867 01
KB14
(1994 Audi 100, S4)
o Replace ignition switch; wash /vacuum vehicle; provide loaner, if necessary
245 T.U. 1 Switch 4A0 905 851L
2 Nut N 011 184 9
1 Nut N 902 867 01
KB15
(1995/96 Audi A6, S6)
o Replace ignition switch; wash car; provide loaner, if necessary
245 T.U. 1 Switch 4A0 905 851J
2 Nut N 011 184 9
1 Nut N 902 867 01
Important: Must enter $7.00 in the Sublet Labor field for vehicle vacuum/wash.
Must enter $25.00 in the Loaner field, if applicable.
9/12
Parts
Disposal
The removed steering/ignition lock switches must be destroyed immediately.

Customer
Reimbursement
Request
Should a customer inquire about possible reimbursement for out-of-pocket expenses
incurred for a previous repair to the ignition switch, please instruct the customer to
make a copy of the repair order and mail the original together with a cover note to:
Audi of America, Inc.
3800 Hamlin Road
Auburn Hills, MI 48326
Attn: Customer Relations - 2F02 (KB)
Additional
Campaigns
Some of the vehicles may be involved in an additional action. If so, the respective
code has been printed on the recall authorization form, as well as on your vehicle
allocation list. In the interest of minimizing customer inconvenience, please ensure
that any such additional campaign action is performed at the same time.
For verification, always check your V-Crest recall system. The V-Crest is the only
campaign verification system; other systems are not valid.
Dealer
Obligation
To ensure customer satisfaction, as well as minimize inconvenience, dealers are
urged to service each vehicle at the scheduled service appointment time and make
sure that each vehicle is returned to the customer washed and cleaned inside. Do
not let any customer wait longer than necessary during service of the vehicle.
Provide a loaner vehicle, if necessary. Every effort should be made to reduce
inconvenience to customers.
Audi of America, Inc. is determined to complete as many vehicles as possible within
six (6) months of initiation. We will mail a gift to those customers who comply within
this time frame. For this reason, we ask that you ensure that each claim is
entered into the system in a timely mannerafter you have completed the recall
work. This will enable us to send gifts to qualifying customers.
Dealers are to service each vehicle subject to this recall regardless of mileage, age of
the vehicle or selling dealer, from this time forward.
10/12
Service
Help
If you have any questions regarding this recall or any other recall or service
action campaign, please feel free to contact me at (810) 340-4850 or
John von Hollen at (810) 340-4858.

Dealer
Personnel
Information
Please make sure that every person in your dealership who has recall-related
responsibilities is familiar with this communication.
Thank you for your cooperation.
Sincerely,
Andreas H. Steglich
Product Compliance Team Leader
/kbcirc

11/12
April 1996
Dear Audi Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Audi has decided that a defect which relates to motor vehicle safety exists in some 1994 through
1996 Audi vehicles. Our records show that your Audi is one of the vehicles affected by this action.
Defect
Description
Audi has found that some of the ignition switches in affected vehicles may have
been improperly manufactured and could cause electrical accessories, such as the
turn signals, windshield wipers, headlamps, power windows and air conditioning to
malfunction when the engine is started.
Remedy
Your authorized Audi dealer will replace the vehicle's ignition switch free of charge.
Repair
Schedule
Replacement parts and all necessary repair instructions will be available at your
authorized Audi dealer by April 29, 1996.
Anticipated
Repair Time
The corrective work will take approximately 21/2 hours.
What You
Need To Do
Please telephone your authorized Audi dealer and arrange for a service
appointment date after April 29, 1996.
Precautions
You Can Take
Prior to the time that the corrective work can be performed, please make a quick
check of your vehicle after you have started the engine and before you begin driving,
in order to determine whether the turn signals, windshield wipers or headlights are
operating. If they do not operate, switch off the engine and restart and check again,
or call your authorized Audi dealer immediately so that the ignition switch in your car
can be replaced promptly. Do not drive your Audi if the turn signals, windshield
wipers or headlamps do not function after you have started the engine.

12/12
Lease
Vehicle
If the vehicle identified in this recall is a leased vehicle and you, the lessor and
registered owner, receive this notice, please forward this information by first class
mail to the lessee.
Service
Problem Help
If your authorized Audi dealer fails or is unable to remedy the defect free of charge
within a reasonable time, please call or write to:
Audi of America, Inc.
Attn: Customer Relations - 2F02 (KB)
3800 Hamlin Road
Auburn Hills, MI 48326-2855
Toll-free Telephone: 1 (800) 822-2834
If you still cannot obtain satisfaction, you may file a complaint with: Administrator,
National Highway Traffic Safety Administration, U.S. Department of Transportation,
400 Sevenths Street SW, Washington, DC 20590. Telephone: (800) 424-9393
(Washington, DC area: 366-0123).
We regret any inconvenience this matter may cause you; however, we want to make sure that your
vehicle is safe and operates to your satisfaction. Upon confirmation by your authorized Audi dealer
of completion of the necessary repair work, we will mail you a gift in acknowledgment of the
inconvenience you may have encountered as a result of this action.
Thank you for driving an Audi.
Sincerely,
Andreas H. Steglich
Product Compliance Team Leader

TurboEnvy52

ok this is saddd, this was just talked about and given great instructions to just last week