Suspension rattling - help diagnosing root cause

[kyledmb]

Hello all,

Now 18 months into ownership, my 2023 R1T continues to develop new clunks and rattles under normal driving. I have the jounce chirp hopefully fixed with an upcoming service appt. and TSB in hand. However, the chirp is actually my least concerning noise. In the video below, listen for a distinct rattle. It might sound initially like wind noise, but its not (I'm also <25 MPH in the video and coming to a stop). Its also more than just noise. Over the last several months, the truck feels sloppy and all those noises seem to telegraph into the pedal and steering wheel. I've also noticed that, even on All Purpose/Soft, it's a very rough ride. Every little bump in the road, asphalt splice, or manhole cover is a jarring experience.

The Bellevue Service Center inspected the suspension at my request after this rattle started developing, but said everything looks good. I'm losing my mind here. Everyone who rides in my truck is alarmed by the sound. It is no longer enjoyable to drive, and I am leaning towards getting rid of it somehow. I'm skeptical I will get any meaningful help from Rivian.

***there is also some dash rattle near the beginning of the video. Ignore that, too!

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[Jonger1150]

Following....

 

[jpmc86]

I know that sound exactly. I have updated jounce, updated air springs (all over), new hubs and axels (front only). I hear that noise coming from all four corners. I think it’s axel design (play). I have pulled the wheels off and the only thing I find slack is on axels.

That being said, gen2’s make the same sound. I tried it yesterday on a Tri max and it had it too.

 

[The Beast]

When going very slow and taking my foot off of the accelerator or when gently beginning to accelerate I hear a “clunk” sound. No warnings and the 2022 R1T seems fine otherwise.

 

[Papi4baby]

My 23 has these noise as well, but is weird I don’t hear it all the time.

Sometimes is super quiet, it is most notable at slower speeds.

 

[kyledmb]

I know that sound exactly. I have updated jounce, updated air springs (all over), new hubs and axels (front only). I hear that noise coming from all four corners. I think it’s axel design (play). I have pulled the wheels off and the only thing I find slack is on axels.

That being said, gen2’s make the same sound. I tried it yesterday on a Tri max and it had it too.

I had new half shafts as well and it seemed the problem only worsened. It must not be the half shafts themselves, but rather the connection points at either end.

Either way, Rivian bought my nightmare back yesterday. No more suspension issues!

I am concerned you noticed the same thing in the new Trimax. I am considering getting one, but if the suspension rattles like on my Gen1 quad, I might lose my mind.

Was the Trimax you drove brand new? How many miles on it? I know the Gen2s will have a slight chirp from the jounce lines, but I would not expect any rattling or clunking. Certainly Rivian engineers fixed this.

 

[jpmc86]

I had new half shafts as well and it seemed the problem only worsened. It must not be the half shafts themselves, but rather the connection points at either end.

Either way, Rivian bought my nightmare back yesterday. No more suspension issues!

I am concerned you noticed the same thing in the new Trimax. I am considering getting one, but if the suspension rattles like on my Gen1 quad, I might lose my mind.

Was the Trimax you drove brand new? How many miles on it? I know the Gen2s will have a slight chirp from the jounce lines, but I would not expect any rattling or clunking. Certainly Rivian engineers fixed this.

It’s still there, and it isn’t going away. It’s inherent to the motors they use. This Trimax was brand new had about 100 miles.

 

[kyledmb]

It’s still there, and it isn’t going away. It’s inherent to the motors they use. This Trimax was brand new had about 100 miles.

The motors they use? I thought they changed in Gen2 to an in-house motor with updated mounts and such. Gen1 quads had "off the shelf" Bosch motors.

 

[jpmc86]

The motors they use? I thought they changed in Gen2 to an in-house motor with updated mounts and such. Gen1 quads had "off the shelf" Bosch motors.

That did not change the type of motors they use. Both Bosch and Rivian motors are permanent magnet motors.

Why did they buy back your Rivian?

 

[kyledmb]

That did not change the type of motors they use. Both Bosch and Rivian motors are permanent magnet motors.

Why did they buy back your Rivian?

So you think the rattling sound is due to the motor design?

Rivian offered a buy-back due to the extensive service history. 9 trips to the SC with 5+ items. I had everything break. Very happy with Rivian's customer service in the end. I really want to get another one, but the one thing keeping me back is this suspension chatter and clunk nonsense. I'm not willing to go there. I don't want a $100k truck that sounds like its going to fall apart from day 1.

 

[kyledmb]

FYI, I'm currently driving around in my dad's old F-150 that has an extensive accident history and it sounds 100x better driving around my neighborhood that my R1T. I just though, "oh, this is what a vehicle is supposed to sound and feel like driving!"

It was refreshing and infuriating all at the same time. How did the Rivian suspension go so wrong?!?

 

[jpmc86]

So you think the rattling sound is due to the motor design?

Rivian offered a buy-back due to the extensive service history. 9 trips to the SC with 5+ items. I had everything break. Very happy with Rivian's customer service in the end. I really want to get another one, but the one thing keeping me back is this suspension chatter and clunk nonsense. I'm not willing to go there. I don't want a $100k truck that sounds like its going to fall apart from day 1.

I know it is. I’ve heard from internal at Rivian, it’s here to stay. Maybe G3. It’s just part of this design. I’ve learned to look past it. Tons of good stuff in the vehicle otherwise.

 

[kyledmb]

I know it is. I’ve heard from internal at Rivian, it’s here to stay. Maybe G3. It’s just part of this design. I’ve learned to look past it. Tons of good stuff in the vehicle otherwise.

Interesting...

Also, when in high suspension mode, the rattles nearly disappeared. So shaft angle seems to have a big effect on the noise. Why would that be?

 

[jpmc86]

Interesting...

Also, when in high suspension mode, the rattles nearly disappeared. So shaft angle seems to have a big effect on the noise. Why would that be?

Has to do with axel spline engagement, and preload against motors. There is a certain lash allowed.

 

[kyledmb]

Has to do with axel spline engagement, and preload against motors. There is a certain lash allowed.

Ahhh, so specifically this rattle is coming from the end of the half-shaft that engages the drive unit? I guess that makes a lot of sense.

I think a lot of people suspected the half-shaft issue to be coming from the wheel hub side.

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