Ongoing Half Shaft Issues… Looking for Advice

[Djordje]

Hey everyone… hoping to get some perspective from other owners.

I have a 2022 R1T Launch Edition and since taking delivery Rivian has replaced the half shafts at least four times. I typically drive in Standard mode with Auto suspension, so I’m not spending much time in High or Low (which I was told can exasperate the issue).

I just came back from service again and it has me wondering if I should be asking Rivian to dig deeper into what’s going on mechanically. I’m coming up on four years of ownership in March, so I’ll only have one year left on the warranty (I most likely won’t go over the mileage limit by the end of year five).

At this point it feels like there may be something more fundamentally wrong causing the repeated failures… either with my specific vehicle or possibly a design flaw that hasn’t been fully addressed. I usually keep my vehicles for 10 plus years and that was the plan with the R1T… but I’m starting to wonder if this is going to be an ongoing lifetime issue.

Has anyone else dealt with repeated half shaft replacements?
Did Rivian offer any deeper diagnostics, goodwill support, extended coverage, or a more long term fix?

I’d really appreciate any advice on how to approach this with service and whether I should be pushing for a more thorough investigation now while I’m still under warranty.

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[tate16t]

Yes, you should push them on it. What is your repeated Half Shaft symptom(s) that force the repeated replacements? Is it the front or rear they replace each time?

 

[Djordje]

Yes, you should push them on it. What is your repeated Half Shaft symptom(s) that force the repeated replacements? Is it the front or rear they replace each time?

Basically, the issue has always been with the two front wheels. Whenever I would make a hard right or left turn, it would intermittently make a loud clicking sound. Once the wheels are straightened out, the sound goes away. When I was in service recently, I mentioned the issue again and they said they would look at it.

Here are Rivian’s notes on the service invoice:

“Tech confirmed symptom. Lifted the vehicle for inspection and found poor spline interference on both half shafts and hubs. Will require replacement to cure symptoms.”

This is the fourth time they’ve been replaced. After the service, everything is good for a while but then overtime it comes back.

 

[Noplacelikeloam]

Depends what the issues are. Im assuming you are going to PDX or Tualitin SC. They are both top notch (IMO) and go above and beyond to make customers happy do they might be replacing out of an abundance of caution. If its a little noise, well thats the design unfortunately. You can stuff them with grease and that will work for about 5K miles and then they are noisy again. If its something else, I would push back for more attention. I suspect a good amount of half shafts have been replaced across the fleet at this point, so its a known issue with early VINs but I would imagine most are remedied by now and after 4 replacements yours should be too.

 

[tate16t]

Replacing half shafts 4 times out of an abundance of caution is cause for concern. If the SC is top notch they should recognize something is fundamentally wrong. I would press them on it now.

 

[DaveA]

Mine have been replaced 3 times. I’ve given up on them fixing it and probably trading in on R2. Still clunks when getting on and off accelerator and clicks and pops at low speed pulling out of garage.

 

[Djordje]

Mine have been replaced 3 times. I’ve given up on them fixing it and probably trading in on R2. Still clunks when getting on and off accelerator and clicks and pops at low speed pulling out of garage.

Thanks for the feedback. It sounds like you’re experiencing the exact same issue I am. I’m getting an intermittent clunking or ticking sound, along with a slight vibration through the steering wheel. It happens intermittently, but typically when there is a change in suspension and the wheel is turned in either direction.

Most often, it occurs when I’m decelerating down a hill and making a hard right… as the front end begins to settle and the wheel is turned, I hear the sound at low speed. I also notice it when accelerating with the wheel turned sharply in either direction… the front end lifts and I hear the same noise.

 

[Nixapatfan]

Did they ever replace the subframe? there were a bunch with broken welds that made loud noises like you described.

 

[CrazyOne]

Did they ever replace the subframe? there were a bunch with broken welds that made loud noises like you described.

Subframe or some other component may be bad and is stressing out the half shafts.

 

[MountainBikeDude]

Thanks for the feedback. It sounds like you’re experiencing the exact same issue I am. I’m getting an intermittent clunking or ticking sound, along with a slight vibration through the steering wheel. It happens intermittently, but typically when there is a change in suspension and the wheel is turned in either direction.

Most often, it occurs when I’m decelerating down a hill and making a hard right… as the front end begins to settle and the wheel is turned, I hear the sound at low speed. I also notice it when accelerating with the wheel turned sharply in either direction… the front end lifts and I hear the same noise.

As touched on above by others, I would be pressing Rivian on the reason for the repeated similar issue, and why the parts, which are seemingly being replaced with updated iterations, are also having the same failures. You seem pretty easy going, so they may push a bit more to get you some kind of answer as to the why.

Be firm, but not a jerk.

 

[MountainBikeDude]

Did they ever replace the subframe? there were a bunch with broken welds that made loud noises like you described.

If the hub assembly and half shafts are being confirmed as having poor spline interface issues, then it's unlikely a result of the subframe.

On that note however, I would have issues with my Gen 1 welded subframe when I was making low speed full lock maneuvers like in a parking lot, or sharp low speed turns. was a bit of a metal on metal twang any time the vehicle altered it's momentum forward or backward. I had pointed to the subframe as being a likely culprit. They went through the list of other possible causes before arriving at the subframe and weld fatigue being the cause, but it was all done during a single service visit.

Edit* It was replaced with a Gen 2 subframe retrofit.

 

[Djordje]

Did they ever replace the subframe? there were a bunch with broken welds that made loud noises like you described.

Yes, it was replaced early on.

 

[Riviot]

Data point: also March 2022 delivery, 70k miles. Original half shafts.

Here are Rivian’s notes on the service invoice:

“Tech confirmed symptom. Lifted the vehicle for inspection and found poor spline interference on both half shafts and hubs. Will require replacement to cure symptoms.”

This is the fourth time they’ve been replaced. After the service, everything is good for a while but then overtime it comes back.

Did they replace hubs too?

Most often, it occurs when I’m decelerating down a hill and making a hard right… as the front end begins to settle and the wheel is turned, I hear the sound at low speed. I also notice it when accelerating with the wheel turned sharply in either direction… the front end lifts and I hear the same noise.

So I was having very similar issues recently and it sounded the same to me, from the front. It was getting progressively worse and I was going to grease my splines at seasonal tire rotation. But, my rear drive unit blew a seal on the disconnect, so I had a rebuilt drive unit replaced in the rear. Original halfshafts are still back there, and all my noise is gone. So...

I suspect one of a few things could be true;
1) Hub bolts need tightening every so often
B. Rear subframe taken off and reinstalled helped ease creaking noises
3c) the noise is coming from something not related to halfshafts and we're all hallucinating

 

[txoutdoorsman]

If the hub assembly and half shafts are being confirmed as having poor spline interface issues, then it's unlikely a result of the subframe.

On that note however, I would have issues with my Gen 1 welded subframe when I was making low speed full lock maneuvers like in a parking lot, or sharp low speed turns. was a bit of a metal on metal twang any time the vehicle altered it's momentum forward or backward. I had pointed to the subframe as being a likely culprit. They went through the list of other possible causes before arriving at the subframe and weld fatigue being the cause, but it was all done during a single service visit.

Edit* It was replaced with a Gen 2 subframe retrofit.

I have had my half shafts replaced twice and I still experience the exact same symptoms you just described - even right after picking up from last service. How best should I approach Dallas SC with this issue? I screenshotted your reply, as you describe the symptoms best

 

[MountainBikeDude]

I have had my half shafts replaced twice and I still experience the exact same symptoms you just described - even right after picking up from last service. How best should I approach Dallas SC with this issue? I screenshotted your reply, as you describe the symptoms best

Yeah if you were experiencing it in a Gen 1 pre mid February 2023 build date, then you have a Gen 1 welded sub frame and it's the likely culprit. It hasn't come back since the retrofit.

Screenshot of the repair invoice for you.

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