Advice on how to fix suspension noise that Tesla can't seem to fix right?

[xanatos]

For some context you can read my previous thread:
How to get service to fix problem that is hard to reproduce?

Basically I started hearing weird groaning/creaking/rattling noises from my front left suspension recently, but only when driving local streets under certain conditions and only intermittently. I have brought it into the Fremont Service center total of 4 times now. So far they have replaced the upper control arm, the sway bar, and cleaned, re-torqued, and lubricated all the suspension parts. They claim they do not see anything else wrong with the suspension (ie sway bar end links, mounts, bushings...)

For the most recent visit I even left the car with them for 1.5 weeks so the tech could reproduce the problem driving to and from work. He reproduced it and swears that by replacing the sway bar the noise has gone away. Unfortunately a few days later I started hearing the same noises again.

The people at Fremont Service have been very patient and nice about everything, but they just can't seem to fix the problem. Every time I go back in, they just keep asking me to go on road tests with the techs, which I am getting sick of and doesn't really help since the problem comes and goes and is hard to reproduce.

At this point I am not sure what to do. Part of me wants to just say screw it and just drive the damn thing, and maybe turn up the music to cover up any noises. But the other part of me says something is definitely still wrong and should be fixed, which involves wasting more time running in circles at the service center.

Any advice for situations like this?

 

[vdiv]

Since the Fremont service has been accommodating try talking to them about replacing the struts. There is something called stiction, the strut seals are sticking when articulated, that causes the strut to sound like it is knocking or rattling. Pretty much every car I've had including the Model S has exhibited this. So far our service department in Tysons Corner, VA has "failed to replicate" the issue. If you have air suspension it could be something similar with the air springs.

 

[neopav]

Hi,


I think I had your same problem.
Rattling exactly from the front-left suspension.
Sometime the noise was there, sometime it disappeared. But you may start laughing when you will find what the real problem is, if it is the same as mine!

I tried several test drives with my car shop specialist, lubricated everything in the suspension etc, with no solution.
We then contacted Tesla service, but also they were not able to identify the problem. They sent to me detailed info about the suspension assembly, and we tried to strenghten everything and lubricating again. No solution.

Then one day, tired by this rattling, I started checking carefully INSIDE the car.
Guess what?
IT IS NOT THE FRONT LEFT SUSPENSION MAKING THE NOISE, JUST THE PLASTIC ASSEMBLY TO THE RIGHT OF YOUR ACCELERATING FOOT!
I just put some foam exactly where the two plastics (upper and lower) make contact to keep them away from rattling, and voilà, no more noise!!!
(as soon as I get home later, I will post a photo to show you the exact position)

I hope your problem is exactly the same as mine, you will resolve it in 5 seconds.

Hope this helps!

 

[Lukez]

Have them look at the brakes. A pad could have failed like it did for me in the rear. I would get a metal sound over certain bigger sharp bumps.

 

[Cgen]

Xanatos, I'm experiencing exactly the same problem on my cpo p85+. I had the service center inspect the car and according to them the suspension and underbody are in good condition. The problem is I couldn't replicate the noise since it's so intermittent. It went away after the last rain so the tech thought maybe there was sand inside the suspension area, but just the other day the groaning/creaking noise from the front is back intermittently. When I hear the noise, I'm usually traveling between 10-15mph on uneven roads, and can hear it more when I'm on regen and the weight of the car is shifting to the front end, and also sometimes when the suspension is raising to very high right before my driveway. I'm probably going to bring up the issue again at the next service. Keep us posted.

 

[K-MTG]

After 3 attempts it seems that Tesla resolved my rumbling issue on my X that was evident during low speeds from the drivers area. Especially when making turns or going over speed bumps. But it came back on my mountain trip a few days ago!!

 

[xanatos]

Xanatos, I'm experiencing exactly the same problem on my cpo p85+. I had the service center inspect the car and according to them the suspension and underbody are in good condition. The problem is I couldn't replicate the noise since it's so intermittent. It went away after the last rain so the tech thought maybe there was sand inside the suspension area, but just the other day the groaning/creaking noise from the front is back intermittently. When I hear the noise, I'm usually traveling between 10-15mph on uneven roads, and can hear it more when I'm on regen and the weight of the car is shifting to the front end, and also sometimes when the suspension is raising to very high right before my driveway. I'm probably going to bring up the issue again at the next service. Keep us posted.

Thanks for sharing, I can't believe you have the exact same problem! I least now I know I am not paranoid. What you described is what I observed as well. It seems like at slow speeds, when stress is being placed on some component of the suspension, mostly when accelerating or decelerating (ie strong regen), something is flexing or rubbing against each other and causing that groaning noise. It almost sounds like a creaking rocking chair or old bed springs.

I think in my case it might be happening more often when there is moisture in the air or during rainy days, but I haven't been able to fully test out that theory yet. Also it seems to happen more if the car is heavy (ie 4 adults in the car instead of just me). I also noticed it a few times when I was stopped at a red light at an incline, and when it turned green and I accelerated, I heard the noise. It's like when too much weight is on something, it creaks.

If I find out more I will let you know. Likewise if you find out the solution let me know too!

 

[Art VandeIay]

Hi,

Then one day, tired by this rattling, I started checking carefully INSIDE the car.
Guess what?
IT IS NOT THE FRONT LEFT SUSPENSION MAKING THE NOISE, JUST THE PLASTIC ASSEMBLY TO THE RIGHT OF YOUR ACCELERATING FOOT!
I just put some foam exactly where the two plastics (upper and lower) make contact to keep them away from rattling, and voilà, no more noise!!!
(as soon as I get home later, I will post a photo to show you the exact position)

I hope your problem is exactly the same as mine, you will resolve it in 5 seconds.

Hope this helps!

This sounds like the same situation I'm having... I can hear the rattle coming from the left side of the car, but not quite sure its coming from any suspension component.

@neopav I would highly appreciate if you could upload the photo of the exact position of your rattle, and the type of foam you used to fix it.

 

[doctordoak]

After 3 attempts it seems that Tesla resolved my rumbling issue on my X that was evident during low speeds from the drivers area. Especially when making turns or going over speed bumps. But it came back on my mountain trip a few days ago!!

K-MTG, I have a one month old Model S with the exact same symptoms. Kind of like a crunchy noise from the left driver's side when going over bumps slowly. Emailed my service center today.

 

[nuronce]

I’ve been complaining for 1.5 yrs with17k on the car.
They ended after doing the same 2x that didn’t do anything something about the brakes probably shaving them

that I need to change the brakes and rotors and MAYBE it will go away but not under warranty