Front frame sub assembly replacement for popping sound

[Nickz]

***UPDATE***
I decided to have the front suspension sub- assembly “retrofit” which resolved the popping sound I was experiencing. Overall, the suspension is much quieter with less clunks and rattles. The service center quoted a day to do the work but it ended up taking a week.

Hi all -

My low 3,000 series VIN 2022 R1T has had a popping sound when turning at low speeds since delivery. I thought it was the known half shaft issue, but I had the customer campaign completed a few months ago where the service center installed the washers, which did not resolve the popping sound.

Fast forward a few months and I’ve moved and taken the truck to a new service center where I took a technician on a ride along. He acknowledged the popping is not the half shaft issue. He said he would need to do some diagnosing to determine the root cause. The conclusion was that for these types of issues for early build trucks like mine, the typical course of action is to replace the front frame subassembly. He stated the assembly was not cracked but replacing it is needed to see if it resolves the popping sounds.

I’ve seen other posts where early builds have had frame sub assemblies replaced due to cracking, but I’m curious if others have had any similar issues. Also, I’m wondering if I should ask service to replace the rear sub assembly as well.

Thanks!

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[mikehmb]

(apologies I have no information regarding your situation, but they were concerned about my front subframe until they finally found someone who could do a proper alignment)

Question - was your ride-along tech a factory tech or someone from the SC?

I had a Factory guy come with me recently and he got a ton sorted out just by ear that I wasn’t even paying attention to. Those people -really- know their stuff.

 

[Nickz]

Alignment has also been a concern. My tires are generally in good shape but the front passenger was being significantly worn at its outer edge due to being out balance. Unfortunately my move involved me moving farther from Normal, so the technician was a service center tech.

 

[DaveA]

I too have an early R1T (mid 3000) but still have clunking getting on/off throttle after the washer treatment(twice) etc and I believe it is simply the hub tolerance is too great, but I mentioned the subframe to the Austin SC and they didn’t mention it having any issues…but I am pretty confident I was just being blown off. ?.

 

[Nickz]

The subframe assembly replacement seems like it would be fairly invasive, so I’m slightly apprehensive but also don’t want the issue to get worse.

 

[mikehmb]

Alignment has also been a concern. My tires are generally in good shape but the front passenger was being significantly worn at its outer edge due to being out balance. Unfortunately my move involved me moving farther from Normal, so the technician was a service center tech.

To clarify - they are deploying corporate techs into the field to help clear the backlog at SCs. The guy who helped me was a corp tech, but deployed (that week) at the South SF SC.

 

[Dark-Fx]

I was getting popping driving over thresholds and low speed turns, and Rivian replaced one of my suspension dampers. Not saying that's what's wrong with your vehicle though.

 

[Nickz]

I was getting popping driving over thresholds and low speed turns, and Rivian replaced one of my suspension dampers. Not saying that's what's wrong with your vehicle though.

Did that resolve your issue?

 

[Nickz]

I was getting popping driving over thresholds and low speed turns, and Rivian replaced one of my suspension dampers. Not saying that's what's wrong with your vehicle though.

To clarify - they are deploying corporate techs into the field to help clear the backlog at SCs. The guy who helped me was a corp tech, but deployed (that week) at the South SF SC.

That makes sense - thanks. I’m served by the Denver service center, which is pretty sizable and I’m hoping has seen enough vehicles to build a sufficient knowledge base. Fingers crossed.

 

[Dark-Fx]

Did that resolve your issue?

Yes it did.

 

[Riviot]

I was getting popping driving over thresholds and low speed turns, and Rivian replaced one of my suspension dampers. Not saying that's what's wrong with your vehicle though.

????? 2022 32xx VIN here. I had the same issue/result above after going in for unrelated issues. I had a window that wouldn't calibrate and changing wheels to 33" diameter as a priority, and might as well knock out half shaft washer FSAM while it's there...

During the half shaft inspection they found a crack in my rear subframe (replaced) and oil leaking from rear dampers (replaced). Between all that and washers added to half shafts, my tocking and clicks went away... For about 1000 miles. The noise came back for a bit, but eventually went away when it got cold out. It very well could still be back, but I was so used to it I didn't care or notice.

I couldn't feel it in the pedal, so it didn't bother me none. I drive by feel, not noise, so ??‍

 

[suprteck]

I had my front subframe replaced with the updated part due to cracked welds. It would make a clicking noise while taking off and also turning the steering wheel back and forth in park. Previously they replaced the ting washers and half shafts. Noise seems to be gone now. Took over a month to get done by the way at SSF service center.

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