I first posted to this forum on April 7, 2018 regarding the strut rattle problems that I started experiencing immediately after delivery of my 2018 75D with 19" wheels/tires in late March 2018.
In July 2018, Tesla engineering designed what they called a "temporary fix" that they installed in my car as a prototype. They said that it hadn't yet been tested for durability, but that it would temporarily take away the strut rattle. And, they said the temporary fix required that they switch my 19" wheels/tires to 21" wheels/tires. Though the invoice didn't include part numbers for the temporary fix, this is what it said:
Corrections: Spring and Damper Assembly - Front - RH
Engineering provided updated struts and 21" wheels and tires as a temporary fix for the issue. they car currently working on a permanent fix that will be released in the near future. we will install it when available.
Corrections: Spring and Damper Assembly - Front - LH
Engineering provided updated struts and 21" wheels and tires as a temporary fix for the issue. they car currently working on a permanent fix that will be released in the near future. we will install it when available.
After the temporary fix was installed and the 21" wheels/tires were put on, the rattle completely disappeared. Tesla Engineering told me that the "permanent fix" should be available in mid-September 2018, and that the "permanent fix" would work on 19" wheels/tires and 21" inch wheels/tires (and they said that, due to all I've been through, I could have my choice of either size wheel/tire set once the "permanent" fix was installed).
On Sep. 18, 2018, the Dublin SC in California had me bring my car in to get the "permanent fix" installed. I told them that I wasn't yet sure if I wanted the 19" or 21" wheels/tires, and they said they would first put in the 19" set and then I could let them know in two weeks if I wanted the 21" set instead. Here are the details of what they did to "permanently" fix my struts:
This is a fix for this customer from Engineering part 1067361-77-C. This is an ongoing tool box case.
Correction: front suspension (including hubs)
Corrections: Air Spring Module - Front - LH
Technician replaced the front left air spring module
Parts replaced or added:
Air Spring Module FR - MS2 DM
(1067361-77-C)
Corrections: Air Spring Module - Front - RH
Technician replaced the front right air spring module
Parts replaced or added:
Air Spring Module FR - MS2 DM
(1067361-77-C)
On Sep. 26, 2018, I picked up the car. The 19" wheels/tires were back on, and there was no strut noise. I told Dublin Tesla that I would let them know within two weeks if I wanted the 21" wheels/tires.
Five days later, I decided I wanted the 21" wheels/tires, so I called the Service Manager and Advisor whom I had been working with. I didn't hear back from either of them, so I continued calling every day, but never heard back till the 9th day. At that point, I got an email from the Service Manager saying that they got rid of my 21" wheels/tires (the set that Tesla had promised I could keep if I wanted them).
Additionally, after two weeks, the strut rattle has come back. It started off happening just a bit, once in a while, but it is increasing every day.
Needless to say, I know this is a first-world problem, but I am disappointed at this ongoing ordeal. Yesterday, I called the Tesla engineer who designed the strut fixes, and he said there's nothing he can do...and he said no one else has complained about the "permanent fix". I now have an appointment with Dublin Tesla for Oct. 23rd for them to re-diagnose the situation.
Has anyone else had their air modules replaced with the supposed "permanent fix" parts 1067361-77-C and found the rattle reappearing after a while?
Thanks for any feedback anyone can share!