1. The rattle is caused by the actuator rod on the waste gate. The tension setting on this rod is required for correct operation but in turn causes some resonance/vibration at certain RPM.
2. They initially thought a new turbo replacement will resolve the issue. They sent out a TPI but have since retracted it as it wasn't fixing the cars.
3. They are working on another solution... no time frame given. The solution is for customer satisfaction purposes not operational purposes. In other words, this will not cause any sort of mechanical failure (or so they say...) but instead is more of an annoyance to the customer.
Also, since the GTI 40 year shares similar drive train as the R, they are also having issues on those cars.
Hope that helps everyone with this issue. At the moment the only solution is an aftermarket down pipe which I am not keen on replacing just yet.
Back to the dealership I go for some other issues I have
I've been following this thread and others like it for a little while, even more so after my Golf R developed this issue - rattling between 1500-2500 RPM when under load.
I put my car in for warranty service at 2439km. The dealership took about one and a half days (I also had a minor issue with a window switch which added to the time for the work). I picked up the car yesterday afternoon and can confirm that the rattling has ceased.
I have also checked my turbo part number (pictures available if requested)
Old: 06K 145 722H
New: 06K 145 722T
It is still early days, but no more rattle.. But it also seems to look like that I might be the exception, not the rule as many people are having to replace their downpipe to fix the rattle.. I'll keep you guys posted..