RS5 Transfer Case Issues Causing Rough Gear Shifts

Having worked on German performance cars for several years, I experienced something very similar with my 2018 RS4. The symptoms you describe match what I encountered, rough shifting and gear grinding between gears, especially noticeable during acceleration. After noticing oil leakage under the car, I took it to a workshop where they diagnosed defective gears in the transfer case. The transfer case oil was badly contaminated with metal particles, which caused the jerky gear changes. The complete repair, including new transfer fluid and replacement of damaged components, cost me 330 Euro. This type of issue typically starts with worn transfer case components that contaminate the transfer fluid. While a fluid change might temporarily improve shifting, the underlying gear damage usually requires proper repairs to prevent further wear. To provide more specific advice for your RS5: How many miles/kilometers are on the car? Have you noticed any unusual sounds during acceleration? Is there any visible oil leakage underneath? When was the last transfer case oil change performed? The repair process and costs can vary based on the extent of gear wear, so these details would help determine if your situation matches what I experienced.

My 2020 RS5 has 162909 KM on the odometer and hasnt had a transfer case oil change yet. After checking underneath, I noticed small oil spots which seems concerning given the symptoms. During hard acceleration, there is a slight grinding noise that wasnt there before. The mechanical wear seems to be getting worse each week. Given the feedback about contaminated gear oil causing similar issues, I will schedule a workshop visit to check the transfer case oil condition before more serious gear wear develops.

Thanks for providing those additional details. The symptoms you're describing match exactly what I experienced before my transfer case repair. The grinding noise during acceleration combined with oil spots is a clear indicator of progressive gear wear, these were the same warning signs I ignored too long on my RS4. Based on your mileage and never having changed the transfer fluid, I strongly recommend getting it checked immediately. In my case, delaying the repair led to more extensive gear grinding and ultimately higher repair costs. The metal particles in worn transfer case oil act like sandpaper, accelerating the wear of other components. My repair timeline went like this: First noticed oil spots at 150000 KM, Grinding noise started shortly after, Complete failure occurred at 165000 KM The total repair ended up at 330 Euro, but could have been less if caught earlier. The workshop found significant gear wear caused by contaminated transfer case oil, similar to what you're describing. For reference, the factory-recommended transfer fluid change interval is typically around 100000 KM. Waiting until 162909 KM likely means you're already experiencing accelerated wear, just as I did.

Thanks for clarifying all the details about mechanical wear and transfer case problems. The grinding noise and oil spots match what others experienced with similar failures. Based on the advice received, it seems getting this checked soon is crucial since my car is already way past the recommended service interval for transfer case oil changes at 162909 KM. The comparison to that RS4 case is helpful, especially knowing how quickly gear wear can progress once these symptoms appear. Will book a workshop appointment this week to get the transfer case oil analyzed before the grinding gets worse. The 330 Euro repair cost mentioned seems reasonable compared to risking more extensive gear damage. Appreciate the detailed feedback about how contaminated gear oil can accelerate wear. This definitely helps confirm my suspicion about transfer case issues being the root cause of the rough shifting. Better to address it now than wait for complete failure like in that other case.