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Looks like I found the root cause of my issue. I have Unplugged sway bars installed front and rear. The bushings, at least on the front, are much stiffer than the factory as they should be. When the temperature drops these must get hard as a rock. Temps dropped down in the 20s here in Nashville so I removed the Unplugged front bar last night and put the stock one back on. When out this morning and took a quick spin. No clunking whatsoever.Clearly an issue with temperature. Driving this week....on Tue/Wed/Thur in Nashville it was in the 20s/30s. Lots of clunking on various bumps, etc. Today it was 56 and not a clunk to be heard. So strange.
We also have a Model Y which does not exhibit this issue.
@whenryb How would the stiffness of those bushings cause clunking? That doesn't make sense to me TBH. The bar should be rotating smoothly within the polyurethane bushings. I've had aftermarket sway bars with polyurethane bushings on other cars without any such issue. I drove those cars in freezing weather all winter long, chasing every snowstorm.Looks like I found the root cause of my issue. I have Unplugged sway bars installed front and rear. The bushings, at least on the front, are much stiffer than the factory as they should be. When the temperature drops these must get hard as a rock. Temps dropped down in the 20s here in Nashville so I removed the Unplugged front bar last night and put the stock one back on. When out this morning and took a quick spin. No clunking whatsoever.
I'll reinstall the Unplugged front bar in a few weeks after we are past any risk of below 40 temps.
I did check the mounting bolts on the sway bar prior to removing and they were tight. I also replaced the sway bar end links with adjustable ones from Unplugged as I was chasing the noise. They were installed, all tight and did not resolve the issue. Removing the bar did resolve it.@whenryb How would the stiffness of those bushings cause clunking? That doesn't make sense to me TBH. The bar should be rotating smoothly within the polyurethane bushings. I've had aftermarket sway bars with polyurethane bushings on other cars without any such issue. I drove those cars in freezing weather all winter long, chasing every snowstorm.
Perhaps an end link bolt was just slightly loose, but at warmer temps it snugged up? I'm not sure that last part is realistic or not (the bolt being more snug at warmer temps). As I mentioned earlier in this thread, I had a front end chunk on this car from a really big hit (huge missing piece of road) that knocked an end link just slightly loose. I couldn't feel anything loose by hand, but the sway bar would shift under load. This was stock sway bar and stock end links.
What is extremely typical with polyurethane sway bar bushings is they need to be re-lubricated periodically. On those cars where I ran aftermarket sway bars I tried many different kinds of lube and while most of them worked, none lasted. The initial symptom of the lube wearing out was just squeaking though, not clunking.
Would that be these parts?Now both sides of mine have started clunking and replacing the lower rear compression arm fixed it. Drivers side 6 months ago and now the passenger. It's the ball joint that attached to the upright, not the rubber bushing which will also tear and start squeaking.
I know everyone's NVH isn't the same root cause, but maybe it will help someone. The compression arm is $165 from Tesla or you can find them for less on Ebay, Rock Auto.
Did you ever replace your drive shafts and did it solve the knocking sound when driving?Tesla just updated their quote. $981. Failed under warranty, they couldn’t diagnose. Now I’m out of warranty and they are happy to fix for almost $1000
its the upper strut mount, a known Problem, KW investigated because costumers complained about noise after installation of their coilovers , they found the original strut mount to be the source and designed a solution:
often the noise comes with temperature drop and goes away after some driving when components warm up.
Is this you?I gave up with playing 'part darts' and just turn up the stereo.
Searching for someone who ships to the US....i ordered a set from KW and will post a update after installation.