I have heard that Audi is actually manufacturing a slightly larger turbo in the newer A4s (98.5 and up). Supposedly this was in response to the multitude of wastegate problems with the smaller Turbos in the early A4s. Apparently the newer turbos does not spin up as fast, but give better boost at higher RPMs. Has anyone else heard anything about this. (Forgive me if this has alreay been alked about...can't search the archives)

Nope, 98.5 has the exact same turbo. The TT high pressure has a different (larger internal diameter/same exterior) turbo. Sizing is irrelevant to the broken wastegate rod issue, in fact unless they respec the rod, there will be the same problems with the TT high pressure turbo.<p>There certainly have been problems with the rod, but there is no multitude. We are up to ten at last count, and we are the high risk category.

My wastegate rod is broken. I really think its a design flaw...Why didn't they go with the external wastegate. That would have saved everyone lots of headache.

I just got my car back from the dealer after the waste gate rod broke. Apparently the reason for the wastegate rod breaking is due to heat coming from the turbo. When the turbo heats up it thermally cycles the wastegate rod leading it to premature failure. The factory fix is to wait until the rod breaks (this is a fail safe condition) then replace the turbo and hence the rod, and also replace the turbo oil cooling hose in case of possible coking and to add a new heat shield to prevent the thermal cycling from occuring again.<p>I can't say the size of the turbo or the impellers changed but the turbo seems to be noticeably stronger than before. I have to take into account that the last time I drove the car it had 0 boost.