Check the headlight actual wiring connector for any corrosion or damage to the pins 1st as it works now but still shows an error,which to me sounds like a bad connection somewhere inside the headlight itself.
Wouldn't flushing matrix before fitting clear any sand leftover or has it formed inside with the metal to cause a partial blockage, I'd have thought they are all flushed & leak, flow tested, but maybe that's more like unicorn talk.
Check if the rear modules are bus linked to the fronts as on some chassis & years, Audi decided to remove direct canbus feeds to rear doors & use the front canbus only & create a bus between the front & rear modules, ideally wiring diagram needed, but it maybe some anomaly linked to this...
I honestly don't think you'd have a case or get anywhere unless you can prove it's got box issues & 100% evidence it hasn't been serviced, even then it's going to be a hard slog.
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