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Cracked forelink?

Discussion in 'Model S' started by JenniferQ, Aug 5, 2017.

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  1. Bill D

    Bill D Member

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    #21 Bill D, Feb 24, 2018
    Last edited: Feb 24, 2018
    JenniferQ - I've just had the same front suspension failure - a cracked Fore Link - on my 13,000 mile P90D so I'm adding my experience here for others because, as you point out, this failure looks like it could cause a serious accident.

    While at the mall, I noticed a clunking sound at slow speed when going over small bumps, so I stayed off the expressway and slowly drove home on local roads.

    After arriving home, I backed up while turning the wheels to right and the car abruptly stopped as the back of the right front wheel jammed solid against the inside wheel well lining.

    The right front wheel was an inch or two back from where it should be. I looked under from the front and saw the cracked Fore Link:
    IMG_1181.JPG IMG_1184.JPG
    Tesla took it to Dania Beach, FL via flat bed and its now being worked on.
     
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  2. zambono

    zambono Active Member

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    Looks like this is an issue we should all be looking at and Tesla needs to look at proactively
     
  3. Az_Rael

    Az_Rael Supporting Member

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    You should consider filing a report with the NHTSA. File a Vehicle Safety Complaint | Safercar.gov | NHTSA
     
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  4. Bill D

    Bill D Member

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    Since this might endanger lives, I probably should file a NHTSA report. I searched this forum to see how common this was. The only thread I found was this one, but there may be others that posted the same failure using different terminology.

    This sure does look like it could cause a serious accident. I feel very lucky this didn't break at high speed on the expressway in traffic or on a jug handle. However, I didn't notice any handling problems after I started hearing the clunking, but I drove home slowly on local roads.
     
  5. JenniferQ

    JenniferQ Supporting Member

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    I did file a complaint with NHTSA but never heard from them. Please do file.
     
  6. Bill D

    Bill D Member

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    #26 Bill D, Mar 1, 2018
    Last edited: Mar 1, 2018
    I filed an NHTSA report. It's interesting that the manufacture date of our P90Ds are one month apart. Bad batch of Fore Links?

    I found the broken-off piece of my Fore Link laying in my driveway. Here's a photo of that piece and the replaced Fore Link:
    IMG_1192.JPG IMG_1193.JPG
     
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  7. myblubu

    myblubu Member

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    Your picture looks like exactly what happened to my 90D. Drivers side front link broke the exact same way. Heard a loud ‘pop’ sound while manouvering in a parking lot and found the exact same broken piece on the ground when the tow truck picked up the car.
    SC replaced both sides with an ‘updated’ part number.
     
  8. sumitkgarg

    sumitkgarg Member

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    When did this happen... just trying to figure out when this "updated" part was available.
     
  9. JenniferQ

    JenniferQ Supporting Member

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    I looked back and don't think I ever posted pics. Here are mine from then. 52358068580__11F146A8-8489-4704-A0C5-ADA6B95D25B6.JPG.jpg IMG_9468.JPG.jpg
     
  10. Bill D

    Bill D Member

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    The SC only replaced my broken Fore Link, not both, but you make me think I should request both replaced.

    This is the sticker on my new Fore Link. I assume it's the updated part number:
    IMG_1201.jpg
     
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  11. Bill D

    Bill D Member

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    Do you recall if they replaced both your Fore Links or just one?

    I'm spooked that my other one may break.
     
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  12. myblubu

    myblubu Member

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    About 2 months ago.
     
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  13. sumitkgarg

    sumitkgarg Member

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    The part numbers for my Sept 17 build, with rattle noise, and steering rack replacement:
    drivers side: P1041570-00-B
    passenger side: P1041575-00-B (same as @Bill D 's replacement part)
     
  14. Speedr117

    Speedr117 Member

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    @sumitkgarg, did replacing those items eliminate the rattle noise?
     
  15. myblubu

    myblubu Member

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    Just looked at my repair order and it shows the same part numbers

    Parts Replaced or Added
    Part Quantity
    FORE LINK ASSY, LH (1041570-00-B) 1
    WASHER, NORDLOCK, 15.2x30.7x3.4 1 (1033093-00-A)
    NUT HF M14x1.50 [10] ZnNi NL INSERT 1 (1004358-00-C)
    Corrections: Link - Front Suspension - Lower - Fore - RH
    Technician installed Left front lower fore link and torqued to tesla specifications. Technician verified after work completed the forelinks are installed as designed.

    Parts Replaced or Added
    Part Quantity
    FORE LINK ASSY, RH (1041575-00-B) 1
    WASHER, NORDLOCK, 15.2x30.7x3.4 1 (1033093-00-A)
    NUT HF M14x1.50 [10] ZnNi NL INSERT 1 (1004358-00-C)
     
  16. sumitkgarg

    sumitkgarg Member

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    Never replaced these parts.. these parts came with the car from factory. rattle noise still exists. they replaced the steering rack assembly but the noise persisted.
     
  17. zambono

    zambono Active Member

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    We need to make sure we keep tabs on how many of these fails and if there is a pattern with build dates and such.
     
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  18. P85Dave

    P85Dave Member

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    Is this caused by metal fatigue? Any way to detect this before a failure?

    If you are making a left turn with oncoming traffic at high speed this could be nasty.
     
  19. JenniferQ

    JenniferQ Supporting Member

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    They replaced both of mine.
     
  20. P85Dave

    P85Dave Member

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    Has anyone managed to get these replaced with an improved party before failure?
     

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