NHTSA Complaint #11516211 — 2012 AUDI Q5

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.