NHTSA Front Suspension Noise/Clunking

[Popobawa]

Hi all:

I am starting this thread to hopefully collectively report to NHTSA on Rivian front suspension clunking/thumping/noise.
while going over bumps it feels like something is loose or will just fall apart.

I have 2024 R1S that I got March last year and since then have been having this issue which is getting worse. it has abt
10,000 miles now. I have taken into service 2-3 times over the year with this complaint, I was told everything is normal.
some how from my service history it has been taken out twice for some reason by Rivian. I have no idea why.

I feel everyone who has this issue should file a complaint with NHTSA ( I just did). This can be a safety issue, it only takes one
to cause terrible outcome, if we can minimize the risk or have company addresses it that might prevent even one mishap, then
this effort is worth it.

Also by doing so we can bring Rivian to table to address this rather then sweeping it under the rug as normal, it surely doesn't feel
normal.

Sooner or later these noisy parts are going to wear out and if car is out of warranty I am sure it will be expensive to repair.

There is always Power in numbers.

attached pls find the link.

https://www.nhtsa.gov/report-a-safety-problem#vehicle

Lastly, I will be opening another ticket with Rivian.

Thank you all in advance for being part of this campaign.

Sincerely,
Doc.

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[electruck]

Noises don't inherently constitute a safety issue and I am not aware of any unaddressed safety issues (Rivian has previously addressed issues of improperly torqued fasteners). Since my R1S doesn't make any noises that concern me (although, yes, it does make some minor noises that conventional suspensions don't), can you share video demonstrating what you're experiencing in your vehicle and are wanting people to report to NHTSA as a safety issue?

 

[MountainBikeDude]

While i know the suspension can sound "loose" there are times where that loose sound isn't necessarily coming from the suspension itself, i t can originate from the trim that lines the top of the frunk. If you go around with the frunk open and tap your finger along the trim, esspecially the front piece as it rounds the corner. Sometimes there can be just enough play in those clips to allow it shift/vibrate.

Just an observation as well, I know the suspension can have a loose feel, but I had similar issues with my Xterra, and Pathfinder. I was at the point where I was literally swapping off different components each month, in a maddening attempt to rectify it. In the end it really was just normal, and there was nothing I could do aside from accept it.

 

[mpshizzle]

I can only speak from my personal experience, but I would say that the R1 suspension makes way more noise than any other vehicle I've owned.

That said, I've also never had another vehicle with air suspension that has such a wide range of adjustability and tunability. While it is certainly the noisiest I've ever experienced, that does not mean that it's loud by any means. And nothing has ever sounded broken to me.

As @MountainBikeDude said, it may sound loose, but that is not necessarily the case. That's just a side effect of highly flexible and adjustable off road suspension

 

[Popobawa]

Hi:
Just to give better perspective.

I used to be a petro head with building my 1st engine at age 16z

I have owned numerous cars over the years. And this noise is not normal.

Over the years have been blessed to own Xterra, Taco, 4 runner, eagle talon , ford probe GT, Mitsubishi Eclipse, Porsche panamera turbo s, few Benz AMGs, few range rovers .

Since going full electric 4 years ago. currently own Benz 580 suv, G580, CyberBeast, rivian R1s.

That being said. I am just trying to bring awareness.
As a doc sometimes you have a hunch.

attached pls find audio file.

also, pls think of this as an awareness campaign.
if something can be fixed to avoid unfortunate outcome or costly repair after warranty then I say why not,


Thanks.
Doc

 

[Popobawa]

Sorry it’s not letting me attach files. I think clip is long will fix and attach later today.

Thanks.

 

[cohall]

My front suspension is noisy as hell at low speeds, but it’s not a safety issue. Service center has confirmed multiple times that everything is tightened to spec and operating normally. It’s just a bad design on the earlier versions of the vehicles.

 

[kyledmb]

Sorry, just adding my experience here...2 years with 2 different R1Ts (both Gen 1 and 2).

1. The noise is not necessarily from the suspension. Yes, the dampers and jounce sub-assemblies can make noise, but a large amount of the clattering/rattling sound at low speeds is actually drive-line related (drive units, halfshafts, wheel hub/knuckle, etc.).

2. It is a complete disservice to refer to this issue as simply a noise complaint. It starts as a noise, but as noted in numerous other threads, it develops into slop/play in the driveline. Noise is one thing, but driving a vehicle that feels loose and impacts the steering and feeling of control is a big issue.

 

[UnsungZero_OldTimeAdMan]

Short answer: It's a truck

Long answer: It's a truck with long suspension travel. As such there needs to be certain amount of tolerance between suspension and drive line components, so that they can retain full range of motion and not destroy themselves. Certain amount of noise may indeed be normal and necessary. Plus, it's still a machine. Machines make noise. This common expectation that EVs are dead silent... it's an irrational myth. The combustion engine is gone, along with its noises, but the rest of the "car" is still there, along with their noises. Many of which you never noticed before because of the combustion engine. The suspension, drive shafts, steering rack, tie-rods... all there.

As long as the noises do not sound destructive (shearing, tearing, grinding) and there are no signs of destruction or high friction (burning smells, smoke, fire, trail of shedding debris, etc.) and don't affect your ability to drive and maintain control, it is NOT a safety issue for NHTSA to be bothered with—whose resources are now more diminished than ever because of politics.

Rivian has already issued a TSB on excessive half shaft play (which can produce the clunking sound), like more than 2 years ago? They have even replaced entire subframes under warranty for some people. Attempting to have NHTSA open an investigation—and [hope to] force a recall—could take more than 6 months or years. If you are serious about resolution, it's not a productive direction.

Instead, find a road or location where you can get the issue to manifest consistently. Document it to show Service. Better yet, you can just show up at the SC and request for a tech ride-along. If they agree the problem is excessive, they can set you up with an appointment once back at SC.

If you just can't accept the fact that a truck with long travel suspension could make noises, then this is not the vehicle for you. Sell it and move on.

 

[tjrivian]

Better yet, you can just show up at the SC and request for a tech ride-along. If they agree the problem is excessive, they can set you up with an appointment once back at SC.

You can do that? Like literally just show up at a Rivian SC whenever you feel like and request a tech to ride in your car and they will accommodate your request?

 

[mpshizzle]

You can do that? Like literally just show up at a Rivian SC whenever you feel like and request a tech to ride in your car and they will accommodate your request?

Depends how nice you are to them. A little good rapport goes a very long way with the SC folks

 

[UnsungZero_OldTimeAdMan]

You can do that? Like literally just show up at a Rivian SC whenever you feel like and request a tech to ride in your car and they will accommodate your request?

I literally heard service advisor say it at the Lake Forest CA SC. With techs being summoned to the front lobby to ride with 3 waiting owners. And yes... "honey gets you bees".

 

[Kaiju]

I'll mention one thing I discovered in a recent service appointment. I had put a ticket in for suspension clunk/thumping. At the bottom of a bump it would make a clunking noise and in often I would feel the thunk through the floor. Figured something was loose or I had bad bushing somewhere. A tech went on a test drive with me over a rough road and identified it. Then we took a similar loaner vehicle out with the same suspension settings and duplicated it. So it wasn't just my truck.

I didn't see a description of what suspension settings you're using or if you have a dual or quad motor, however in my case the actual cause was the air suspension hitting its travel limits. I was bottoming the air suspension out. I had been using soft suspension and standard height and for whatever reason that was enough to hit the stops on the air springs when I went over something that made the front end dip enough. Switched to moderate and the problem stopped.

While I can't say this is your problem in particular, if you drive in soft or in low it's worth testing.

 

[Popobawa]

2024 rivian R1s dual performance max pack. its does in modes firm to soft. I drive in standard height. Also FYI to some ppl in this thread I am very highly educated individual and have great deal of knowledge of mechanics etc etc related to automobile as it’s my hobby. As I said before this thread is just a campaign for those who feel Rivian keeps telling them it’s all normal until something goes wrong.

when Johnson and Johnson covid vaccine got approved and came out, it was reiterated multiple times by manufacturers it’s safe until it wasn’t…..I always had a hunch about it and never recommended it to my patients.

knowledge is power and there is More power in numbers.

Thanks.

 

[mpshizzle]

2024 rivian R1s dual performance max pack. its does in modes firm to soft. I drive in standard height. Also FYI to some ppl in this thread I am very highly educated individual and have great deal of knowledge of mechanics etc etc related to automobile as it’s my hobby. As I said before this thread is just a campaign for those who feel Rivian keeps telling them it’s all normal until something goes wrong.

when Johnson and Johnson covid vaccine got approved and came out, it was reiterated multiple times by manufacturers it’s safe until it wasn’t…..I always had a hunch about it and never recommended it to my patients.

knowledge is power and there is More power in numbers.

Thanks.

I think the issue you're seeing on this thread is that relatively few people here seem to share the sentiment that something is wrong with their vehicle, and therefore do not feel inclined to join the cause

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