Clacking noises in the footwell area

[ruffieuxh]

Hello everyone,

My 2013 MS with 250'000km (160kmiles) is making clacking noises in the footwell area on the driver's side when I drive over cobblestones (really bad) or any other bumps or humps. It sounds similar to when you turn off the faucet in a house very fast and the piping vibrates as a result.

I am a car engineer myself and my first thought was that there must be a loose pipe in or around the battery pack.

On the lift we found out that all 4 front suspension arms are worn out (known MS problem). One of them was making a similar noise. Although I had my doubts, we replaced these control arms first, because they needed to be replaced anyway. I had my doubts because the noise sounds like a springy object hitting the chassis. Worn out suspension parts typically sound different in my experience because they are constantly under load and therefore sound less "springy".

After having changed the suspension arms, the noise is still there as I thought. After looking at it again, we found out that the problem could rather come from the steering gear. When the car is switched off (no power steering) and you move the steering wheel very fast back and forth, you hear a similar noise. The same is true when you turn the steering all the way to the max on the lift. You can then virtually feel the noise with your hand on the steering gear.
The steering rods, on the other hand, do not seem to be worn out and the steering arms (connection to the wheel suspension) also seems to be fine. Our "best guess" was that either the rack and pinion steering needs to be adjusted or in worst case needs replacement.

Does anyone already know about this problem? If so, I would be glad about hints, what else could cause such a noise.

Best thanks and greetings

Heinz

Translated with www.DeepL.com/Translator (free version)

 

[N2itive]

I think if you can make a quick audio recording it would be helpful.

 

[murphyS90D]

There was a recall because of failed steering rack bolts. I don't know the year range but my 2016 started making noises with the steering wheel at either end of the rotation.

 

[PCMc]

The steering bolt recall which @murphyS90D referenced is for Model S vehicles built before April 2016. You should (at least in US) have received notification from Tesla about this.

Here's link to details on Tesla's site: Model S Steering Assist Motor Bolt Recall

 

[rooter]

That's not what it is. It's the Foot Chopper that's gone loose. The Foot Chopper rarely activates in only very particular conditions, which are kept secret by Tesla and the hacking community.

Take it in to Tesla, describe the problem and tell them 'you know what it is'. They'll understand.

 

[ruffieuxh]

I think if you can make a quick audio recording it would be helpful.

Thanks.

Tried it, but unfortunately this noise is very tricky to record...

 

[ruffieuxh]

There was a recall because of failed steering rack bolts. I don't know the year range but my 2016 started making noises with the steering wheel at either end of the rotation.

Thanks.

Could have been, in deed. But those bolts had been replaced long time ago.

 

[ruffieuxh]

That's not what it is. It's the Foot Chopper that's gone loose. The Foot Chopper rarely activates in only very particular conditions, which are kept secret by Tesla and the hacking community.

Take it in to Tesla, describe the problem and tell them 'you know what it is'. They'll understand.

Thanks rooter,

May I ask, what ist the "Foot Chopper" is?? Not even my translator offers a sensible solution.

Remember: it sounds pretty much like a loose tube knocking against the chassis.

Thanks

 

[rooter]

The Foot Chopper chops off the feet in circumstances where they might be injured, such as in an accident. This saves a good amount in medical bills. It's installed in all Teslas.