NHTSA Complaint #11716617 — 2019 AUDI E-TRON

The high-voltage charging flap assembly (Part 4KE810001) has failed, preventing the charge door from latching. Notably, this failure (DTC P31D000) occurred within 7 days of the vehicle being serviced at Audi Burlingame for a high-voltage battery software recall. This presents three safety hazards: 1. Driver Distraction: Triggers a continuous auditory chime and 'Warning! Please check the charging unit cover' message every 10 seconds. It cannot be silenced, creating a severe, persistent distraction. 2. Unintended Deployment: At highway speeds, the unlatched flap opens/flaps due to aerodynamics, creating a visual obstruction and distraction for the driver and traffic. 3. Moisture Ingress: Failure to seal the port exposes the high-voltage interface to pressurized rain/road spray. Per NHTSA 19V434 (Recall 93E8) regarding moisture ingress in this system, this failure represents a recurrence of a known safety risk. Evidence of Defect: Audi has iterated through three versions of this part (4KE810001, B, and C), confirming an inherent design flaw. This component is specifically identified in Service Campaign 93H6 for proactive replacement. Despite this, and the failure occurring immediately after recall service 93V2 on October 1st 2025, Audi Burlingame denied a 'goodwill' repair and quoted $1,100+ for a part already internally flagged as defective. Repair declined due to cost; safety hazard remains active. I am requesting that the NHTSA open an investigation into this component failure. Thank you,