Clunking sound from front end.

[Jonger1150]

Problem is, it's more than just an annoying noise. I really do think this slop in the half shafts eventually damages the drive units, causing a need for replacement. Nobody wants that.

Possibly. It's not a violent smack, but those little knocks might add up in the end.

I wonder how the engineering team let that go. I would assume they had to run out of options as to how to connect a complex adjustable suspension.

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[kyledmb]

Possibly. It's not a violent smack, but those little knocks might add up in the end.

I wonder how the engineering team let that go. I would assume they had to run out of options as to how to connect a complex adjustable suspension.

I'm almost positive that members on this board have stated Rivian replaced drive units due to this half-shaft play. Some even reported a fluid leak at the spline side connection to the drive unit. I believe these leaks form over time due to the half-shaft design and compromise the drive unit.

I could be totally off-base here, but adding all things together this makes the most sense to me.

 

[DaveA]

Problem is, it's more than just an annoying noise. I really do think this slop in the half shafts eventually damages the drive units, causing a need for replacement. Nobody wants that.

Are we sure we don't want that? That could fix everything.

 

[Jonger1150]

I'm almost positive that members on this board have stated Rivian replaced drive units due to this half-shaft play. Some even reported a fluid leak at the spline side connection to the drive unit. I believe these leaks form over time due to the half-shaft design and compromise the drive unit.

I could be totally off-base here, but adding all things together this makes the most sense to me.

I actually forgot about that. Well, if there is no fix for the half-shaft by June 2027 this truck will be turned in. If there is a fix, I'll buy out the lease.

 

[Jonger1150]

Are we sure we don't want that? That could fix everything.

Hmm... maybe I could build a small automated machine to work the half-shaft back and forth until it leaks oil. I can't post my early design here since it might get flagged as X-rated.

 

[kyledmb]

So the last couple nights were low 40s here. Today, the rattle is nearly gone. I didn't do a ton of driving, but what I did was night and day.

 

[R1Tom]

Possibly. It's not a violent smack, but those little knocks might add up in the end.

I wonder how the engineering team let that go. I would assume they had to run out of options as to how to connect a complex adjustable suspension.

This is definitely possible....the bearings in the drive units most likely don't like those lateral impact loads...so over time...could develop play...and as that get worst...eventually causing seals to fail or the bearings themselves could fail.

On the plus side....they are covered for 8 years or 175k miles...whichever comes first in the G1 QM.

 

[Jonger1150]

So the last couple nights were low 40s here. Today, the rattle is nearly gone. I didn't do a ton of driving, but what I did was night and day.

I do want to ask them to inject grease into the splines

 

[R1Tom]

I do want to ask them to inject grease into the splines

I assume the cold temps result in the grease becoming more viscous and thus dampens the axle spline movements resulting in less noise. It would seem they should be able to come up with a way to permanently dampen this movement regardless of temp.

 

[Jonger1150]

A grommet mounted to the shaft side so it can bump on the motor spline and hub spline.

I think it would possibly wear out over time.

 

[llacii]

So the last couple nights were low 40s here. Today, the rattle is nearly gone. I didn't do a ton of driving, but what I did was night and day.

It was 39 here the other morning, and I'd say my R1T loaner sounds only very slightly better on soft, still generally way too clunky, and when switching to firm it was still very harsh hard metal clunks on front and back when going over speed bumps. Late this afternoon service said my R1S with new dampers (at all 4 quadrants) is supposed to be done by Monday, but a few hours later I noticed the car was moved to a new parking spot and the ticket says service is complete - I wonder how quick damper replacement is, can all 4 be done in a couple hours? Earlier I did send them a message to inspect half shafts as well but they said they did that at my previous service a few weeks ago and in their opinion "that wasn't contributing to the noise" (ie won't be looking at it again).

 

[Electrified Outdoors]

Checking back in on this issue. Can anyone confirm if the dampers fixed the issue for them?

 

[Jonger1150]

Just got mine back from the service center for the PTC install and tire rotation. Maybe it's the 45F outside, but it's the quietest I have heard yet. Hopefully they didn't shoot grease in the splines to cover it up for a while. Again, the 45F might be the "fix", but I'm kind of certain this reduced some noise. It looks like a new part was added to the hubs all the way around.

 

[kyledmb]

Just got mine back from the service center for the PTC install and tire rotation. Maybe it's the 45F outside, but it's the quietest I have heard yet. Hopefully they didn't shoot grease in the splines to cover it up for a while. Again, the 45F might be the "fix", but I'm kind of certain this reduced some noise. It looks like a new part was added to the hubs all the way around.

perhaps the temps are helping, but this sounds promising! What exactly is the "PTC"?

 

[Jonger1150]

perhaps the temps are helping, but this sounds promising! What exactly is the "PTC"?

Powered Tonneau Cover.

This should reduce the tolerance on the half-shaft play. I guess we'll see.

I had the radio and HVAC off and drove 55 miles. About 2 miles of low speed driving and through a rutted out parking lot where I normally hear it pretty loudly. Silence.

I still have the original dampers which I believe were noise makers, so we'll see about that when I get back in it this evening.

It's promising.

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