Clunking sound from front end.

[jpmc86]

Have we discussed this new RCA?


RCA-18-24-001-1: Tighten Hub to Knuckle Fasteners

Rivian is initiating a customer satisfaction campaign for some model year 2023-2024 R1T and R1S vehicles.

On these vehicles, the wheel hub to knuckle joint may have been assembled with an updated fastener using a torque value intended for the previously-used fastener.

A fastener torqued to the previously-used lower value may cause an audible noise while driving at low speeds but will not impact vehicle performance.

Rivian will retorque the affected fasteners. Rivian is launching this campaign for customer satisfaction and to ensure the quality of Rivian vehicles.

wait - just re-read this. It’s actually on all four wheels, so this just might actually be it. I drove a gen2 last week and it also has the same noise.

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[Jonger1150]

I wonder how much impact this has on half-shaft play. I have been looking at schematics of these parts on different vehicles, but I have zero hands on experience or knowledge on how they connect.

My build date was Jan 2024 so this puts me right in the wheelhouse for this one.

 

[llacii]

My R1S with 22s has had the same clunking noises others reported (coffee can, etc, though to me more like driving over metal buckets) that are especially noticeable over speed bumps in Standard/Firm, but also on little road ruffles. It's been in service multiple times in recent months since it just sounds so bad that I've come to refuse to accept it is normal / within spec. I was just at the service center today for pickup, and last week they did the knuckle to hub tightening on all four wheels (same one noted in previous posts in this thread). Unfortunately I'm sad to report that the knuckle hub tightening service did not fix it. Before taking it, I requested a drive with a tech, we went over speed bumps nearby, and it sounds just as bad as before. Once again they claim this is normal for this adventure vehicle, however that is simply unbelievable as it sounds terrible and it wasn't like this until after the summer ota suspension updates (my best guess). This time though, upon hearing it with me (again) on the test drive, they did say they'll replace all dampers and with it jounce lines as a next step. Really sad to say if they can't resolve again, it'll probably be time to figure out what the heck to buy instead. Also, I got a loaner R1T with 22s that is 2023 like my R1S, drove it over the same speed bumps and then home, and was discouraged to hear it also has the same unpleasant clunks...

 

[Jonger1150]

My R1S with 22s has had the same clunking noises others reported (coffee can, etc, though to me more like driving over metal buckets) that are especially noticeable over speed bumps in Standard/Firm, but also on little road ruffles. It's been in service multiple times in recent months since it just sounds so bad that I've come to refuse to accept it is normal / within spec. I was just at the service center today for pickup, and last week they did the knuckle to hub tightening on all four wheels (same one noted in previous posts in this thread). Unfortunately I'm sad to report that the knuckle hub tightening service did not fix it. Before taking it, I requested a drive with a tech, we went over speed bumps nearby, and it sounds just as bad as before. Once again they claim this is normal for this adventure vehicle, however that is simply unbelievable as it sounds terrible and it wasn't like this until after the summer ota suspension updates (my best guess). This time though, upon hearing it with me (again) on the test drive, they did say they'll replace all dampers and with it jounce lines as a next step. Really sad to say if they can't resolve again, it'll probably be time to figure out what the heck to buy instead. Also, I got a loaner R1T with 22s that is 2023 like my R1S, drove it over the same speed bumps and then home, and was discouraged to hear it also has the same unpleasant clunks...

Bummer, I had hoped this would fix it.

The problem is the half-shafts have too much play between the hub and motor.

Here's a video I recorded of the sound when I put the phone inside the truck and manually move the half-shaft back and forth. This is just my hand moving it, imagine the force this thing is taking from road impacts.



This is a major headache for Rivian and I'm surprised a fix hasn't been made yet. The amount of wasted man-hours just to tell customers that it's normal.

I too will be moving on from Rivian if a similar vehicle debuts that will fit this niche.

 

[Ilovejunebugs]

After my truck had the washers installed and front subframe replaced, it is very quiet, unless it's a very large bump, which I think is normal in pretty much any car.
Hopefully rivian can fix the trucks that remain noisy, as they're great vehicles IMO.

 

[R1Tom]

After my truck had the washers installed and front subframe replaced, it is very quiet, unless it's a very large bump, which I think is normal in pretty much any car.
Hopefully rivian can fix the trucks that remain noisy, as they're great vehicles IMO.

Same with me. New subframe (which comes with bonus new upper and lower control arms and under body carbon fiber cover) and ting washers and it is very quiet now. Just some thumping noise on large impacts, but seems pretty normal now.

 

[Schroederhc]

What year? Is there a recall tsb for that?

 

[DaveA]

What year? Is there a recall tsb for that?

If they inspect your subframe and see cracked welds you get the new subframe and parts etc. I need to have mine looked at.

 

[Jonger1150]

After my truck had the washers installed and front subframe replaced, it is very quiet, unless it's a very large bump, which I think is normal in pretty much any car.
Hopefully rivian can fix the trucks that remain noisy, as they're great vehicles IMO.

Did the washers go on the ends of the half-shaft? Do you have the repair notes from this?

 

[jpmc86]

My R1S with 22s has had the same clunking noises others reported (coffee can, etc, though to me more like driving over metal buckets) that are especially noticeable over speed bumps in Standard/Firm, but also on little road ruffles. It's been in service multiple times in recent months since it just sounds so bad that I've come to refuse to accept it is normal / within spec. I was just at the service center today for pickup, and last week they did the knuckle to hub tightening on all four wheels (same one noted in previous posts in this thread). Unfortunately I'm sad to report that the knuckle hub tightening service did not fix it. Before taking it, I requested a drive with a tech, we went over speed bumps nearby, and it sounds just as bad as before. Once again they claim this is normal for this adventure vehicle, however that is simply unbelievable as it sounds terrible and it wasn't like this until after the summer ota suspension updates (my best guess). This time though, upon hearing it with me (again) on the test drive, they did say they'll replace all dampers and with it jounce lines as a next step. Really sad to say if they can't resolve again, it'll probably be time to figure out what the heck to buy instead. Also, I got a loaner R1T with 22s that is 2023 like my R1S, drove it over the same speed bumps and then home, and was discouraged to hear it also has the same unpleasant clunks...

Dampers won’t fix it. We have the new versions installed. Did they give you an estimate with the new PN’s?

 

[R1Tom]

Dampers won’t fix it. We have the new versions installed. Did they give you an estimate with the new PN’s?

Well there goes one of my thoughts....so if that didn't eliminate it, then I assume it must be the half shafts and that play in the section that allows them to change length...whatever that is called....

 

[jpmc86]

Well there goes one of my thoughts....so if that didn't eliminate it, then I assume it must be the half shafts and that play in the section that allows them to change length...whatever that is called....

Definitely.

They are better, softer (the dampers) and quieter. But the noise were after is half shaft design. They replaced my half shafts, and the hubs - I feel the same noise in the video captured with the phone inside while he moves them.

 

[R1Tom]

Definitely.

They are better, softer (the dampers) and quieter. But the noise were after is half shaft design. They replaced my half shafts, and the hubs - I feel the same noise in the video captured with the phone inside while he moves them.

I did notice that video shows my remaining noise. And I had my subframe, lower control arms, upper control arms, and even one of the half shafts replaced and still have that one remaining thumping/thunking....mostly only noticeable at lower speeds and larger bumps.

 

[DaveA]

Definitely.

They are better, softer (the dampers) and quieter. But the noise were after is half shaft design. They replaced my half shafts, and the hubs - I feel the same noise in the video captured with the phone inside while he moves them.

The truck requires too much articulation with the multiple ride heights, etc. Really wished there was a cheaper, fixed non-air suspension option for this truck and then all the tolerances could be tightened up.

 

[Frisbee]

My first R1T was a LE QM and at around 3,000 miles started having the same problems. Apparently the vehicle could not withstand the torturous driving on paved roads back and forth to the store. Over the next 8,000 miles went through the bandaid repairs (lube and tighten bolts, new washers, etc.), then sub frame replacement and a new front drive unit. Still had the same problems. I requested a replacement vehicle and was ghosted by Rivian for several months. After much complaining (a truly bitter experience) Rivian agreed to replace the vehicle. At my request the replacement vehicle was an R1T DM. While the new R1T only has 4,000 miles what a difference. So far absolutely solid. While not an automotive engineer I think Rivian took on more than it could chew in trying to build a QM vehicle which would be all things to all people - rock climbing at one end of the scale and sport mode at the other end. To much articulation. By the way I am a stockholder in Rivian and certainly back the company. I just think there have been some questionable decisions along the way.

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