NHTSA Front Suspension Noise/Clunking

[ham]

I am taking my 2023 R1T in for the 3rd time in July for noisy front suspension.
Had the same loud noises coming from the front end at slow speeds and clunking at Hiway speeds as the OP.
San Jose service center replaced the front subframe and did some lube on various items.
When I got home there was a large bolt in the frunk, looked new and was at least 3/8 in diameter and 3 inches long, didn't think it was left out since the noise was gone pretty much, thought they just forgot where they put it.
Noise came back a couple months later, took it to the South San Francisco service center that time, the service guy called me and told me the truck was done after a week.
Went to get it and he told me they found a "couple" of missing nuts and a few bolts were not tightened properly, wow not something you want to hear!
So I guess I'll see what is going on this time, it's super loud again...SMFH

SF Area Rivian SCs are incompetent so they'll likely say its in spec and give you the vehicle back with the same issue.

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[RandomMcRandomFace]

Half-shafts and hubs might be the fix for tick / tock / ting from regen or moving from drive to reverse.

You can see my service ticket here and this resolved my issue with the tick / tock / ting at low speeds when driving or stopping / regen / change from Reverse to Drive to Reverse to Drive. Very easy to replicate. Think of doing a three point turn in a tight alleyway from your garage.

yea, I am going to ask about it again before it leaves service. This is super helpful.

 

[Kukulcan]

It may be the right front break pad that is loose in caliper, this makes rattling noise at slow speeds in a bumpy roads.

 

[kyledmb]

It may be the right front break pad that is loose in caliper, this makes rattling noise at slow speeds in a bumpy roads.

Whoa...that's a nasty sound. Can you hear it in the cabin when it rattles around like that on uneven pavement?

I could see that this is an easy thing for an SC to overlook if a customer come in complaining about front-end rattling noises.

 

[variableresults]

My inner IT RCA part wants to chime in to help with this thread. I've made an NHTSA complaint for my suspension, but specifically the subframe. I've done a lot of research on the snaps and squeaks and clunks at this point and have a service appointment next Thursday to address them all. Here is a division of noises that I've come across that is hopefully helpful in bringing specificity.

2022 Gen 1 Welded Subframes
The first R1T and S models had a welded front subframe. Those welds are subject to metal fatigue and can begin creak when turning the steering wheel and going over bumps / grades. This is what I put my NHTSA complaint in because if a weld can fail, that means the subframe is at risk of failing too, depending on where it fails and how.

Note that this issue seems to present more in cold weather, which makes sense with the metal expanding and contracting. I can stay parked and turn my wheel and I'll hear a number of snaps going through the full range. I also get the same snap at low speed when accelerating and stopping.

Ting Washers and Half Shafts
I've seen reports of some of the snaps / pops being caused by the ting washers and half shafts, which the SC has replaced with success. Not sure the safety side of this one since it could just be metal rubbing on metal.

Air Suspension Jounce Lines
This is the one responsible for the squeaks we get going through dips and bumps. There is a Rivian TSB for it and I have a ticket open.

Given OP has a 2024 model, and the welded subframe was replaced with the cast aluminum one by 2023, I doubt the noises are coming from that unless it was an overall bad part or something isn't torqued correctly I would guess ting washers / half shafts. There may be more potential sources, but this is what came up for me since I'm experiencing all the noises right now.

I know there was also a recall for some of the suspension bolts not being torqued correctly, but with a 2024 model I think that would have been fixed already.

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