2012 Audi Q5 Body & Structure Problems

I found out this past summer that my rear subframe on my Audi Q5 (2012) had rusted out to the point of being dangerous to drive. Looking into it, this is apparently a common problem due to the 1st and 2nd generation design of the Q5 where they placed a wind deflector over the rear subframe. In doing so, that wind deflector collected and held moisture and corrosive agents against the frame to the point where it was completely rusted through. I was told my Q5 was not safe to drive until I got the rear subframe replaced. The Audi dealership that I ordered the subframe from (Rockville Audi) said they have been increasing the number of subframes on order as this is becoming a consistent problem. When I spoke with Audi of America about it, they said they did not believe it was an issue beyond regular aging of the vehicle but I disagree as I have other vehicles with many more years that do not have complete sections of the frame rusted/rotted out.

The Rear Subframe was found to have two significant holes that would not allow the car to pass a safety inspection, and I was told a significant hazard that required immediate repair. This is the only part on the vehicle with rust and is the same issue of rear subframe rust that Mercedes Benz is covering under warranty on the same-year cars due to a manufacturing defect. Audi Tysons had serviced the vehicle since new but was negligent in warning me of the extreme rust or safety hazard that had developed. The first inspection by an independent shop found this issue and said it is common on Audi Q5 manufactured in this time frame. According to the repair shop, the part has a plastic protective cover that allowed water to stay trapped and is the main contributing factor. Audi refused any warranty coverage stating the warranty only covers "vehicle body sheet metal panels," but the Owner's Manual for Warranty Coverage states "-- a defect in manufacturer's material and workmanship that will result in rust perforation of the vehicle body". The Q5 is a low-mileage (87,500) vehicle that has been garaged for ~50% of its life in Northern Virginia. In summary, this is a know critical safety issue due to a manufacturing/design defect that Audi is not addressing.

The vehicle sunroof exploded. On March 10th at approximately 12:15pm, while driving down the road from my residence in my 2012 Audi Q5, the sunroof blew up, without warning, causing shattered glass to fall inside the cab of the vehicle onto myself, and my then nine year old son, causing minor cuts, and small pieces of glass to be lodged into the skin of our arms, chest, and head . I called the Audi service ref repairs, and was told it would take three months, before the service department could look at and repair my vehicle, as they were backed up with repairs. I ordered a new sunroof windshield and did a self repair and calibration. I followed up with Audi, advising of the incident, and was told the SUNROOF was under a recall, but their records, this item had been address on my vehicle, no further assistance was offered.

The contact owns a 2012 Audi Q5. The contact stated while driving at various speeds, the rear end of the vehicle was swaying from side to side and was very unstable. Upon inspection, it was discovered that the rear subframe had sustained severe rusting and corrosion, and there were holes present in the sub frame. The manufacturer and local dealer were notified of the failure, but no assistance was provided. The failure mileage was 180,000.

WHILE DRIVING AT STEADY HIGHWAY SPEED AND ALL WINDOWS CLOSED, THE CAR FRONT SUNROOF GLASS SECTION "EXPLODED" QUITE LOUDLY WITH GLASS BITS THROWN INTO THE AIR AND OTHER SMALL CHUNKY SECTIONS FALLING INTO THE FABRIC LINER AREA. HAPPILY NOT INTO THE CABIN. ABOUT 2-3 INCH BROKEN PERIMETER EDGE OF GLASS REMAINS IN PLACE. NO INDICATION OF ROAD DEBRIS HITTING THE CAR (NOR PASSING BY AN OVERPASS OR FROM TRUCK ROOF ETC. OUTSIDE TEMP ABOUT 75F. SEE INCLUDED PICS.

DUE TO EXTREME COLD WEATHER THE REAR SUNROOF GLASS PANE SHATTERED. THE VEHICLE WAS PARKED OVER NIGHT IN NEGATIVE DEGREE WEATHER; NOT IN MOTION. AUDI DEALERSHIP RECOGNIZES THIS AS A NATURAL CAUSED INSTANCE, NOT COVERED BY WARRANTY AND NOT COVERED UNDER THE PAST RECALL, WHICH WAS ONLY FOR THE FRONT SUNROOF GLASS PANE.

THIS IS A DESIGN DEFECT. THE SIDE MIRRORS ARE TOO LARGE AND PLACED IN A LOCATION ON THE WINDOW THAT CREATES A BLIND SPOT AND IN PARTICULAR THE DRIVER'S SIDE THERE ARE INSTANCES WHEN YOU CAN NOT SEE A CAR COMING AT YOU FROM THE LEFT, OR OF YOU ARE TURNING LEFT YOU CANNOT SEE IF THERE IS AN ISLAND. WHILE WE HAVE NOT HAD AN ACCIDENT, IT IS A HAZARD AND SHOULD BE RECTIFIED. THIS HAS GIVEN RISE TO A NUMBER OF NEAR ACCIDENTS AND I HAVE TRIED TO GET AUDIO TO LISTEN TO ME. *TR