Rattle noise coming from front Air Suspension (2017-18)

[Dragetreneren]

I agree partly with the above. Some people go nuclear about small things. However the rattle noise is something Tesla needs to address. The issue here is this may in fact affect a large amount of cars and a ton of people may come and ask for a replacement which can go really $$. Not sure this is an OEM issue and they can put it on them or maybe whatever is around that amplifies it to be heard annoyingly in the cabin is the issue. That would be my guess. If the rod needs room to expand with temperature and a rattle is normal, this aluminum body is just a perfect bass reflex. But if that's the case I am sure the manufacturer has design recommendations to compensate the noise.
This needs to be pushed so they actually do something about it.

OEM implement design specifications set by customer (Tesla). OEM come with recommendations, but it is up to the customer in the end. Unless OEM deviated from the agreed specification customer has no legal grounds to complain.

My assumption is that Tesla will have to deal with expenses. It depends on how Tesla chooses to mitigate this problem but if not taken seriously Tesla probably risks to face uncontrolled expenses. Direct - related to delivered orders, and indirect - related to potential sales etc.

 

[Dragetreneren]

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!

Thank you very much for posting about your experience. Have you been able to get a technical explanation of the problem that you could also post here?

I think your Tesla engineering contact would be very welcome here to answer questions and probably interview owners to get more insight if needed.

There has been a information vacuum. All we know is that the issue with a part of the strut assembly or probably how the parts interact. Somehow the problem propagates via strut tower braces (STB) to the cabin as well. This two effects are related, but the squicking in the midpart in the console (where STB connect to the frame) come AFTER the rattling in strut assembly worsened.

 

[cruiserlarry]

@Electroman My apologies - I didn't realize their were 2 of you lol...

I had my S90D in for service last week, and asked if a new front strut unit has been released to cure the rattle issue and if the part number listed in this thread (1067361-77-C) was accurate. My service writer contacted Tesla in Fremont, and was told "yes" - so she put 2 of them on order for me. She found 2 available at another service center, but they would not release them to her, so I'll be waiting until more are shipped out. She printed a copy of the Service Estimate for me that lists that same part number, so hopefully everyone is providing correct information, and these new units will fix the issue. I'll post once they receive and install them.

 

[Dragetreneren]

Yes! My issue was resolved. I already posted.

They were supposed to email my invoice but never did so I don’t have part number so. I’ll call Monday.

But yes - the rattle is GONE. They actually fixed it.

Do you use R19 or R21 rims?

 

[emmz0r]

Does it sound like there's a loose panel or something in the car? For me it almost sounds like it comes from behind.

 

[Dragetreneren]

Does it sound like there's a loose panel or something in the car? For me it almost sounds like it comes from behind.

If you post video or even better attend your SC you will know.

 

[emmz0r]

If you post video or even better attend your SC you will know.

It's illegal to hold phone and film while driving and I go to work every day so I can't just stop at a SC

 

[emmz0r]

Damn it sounds the same in the videos! Sounds like internal panel rattles, had me fooled. I am getting my car detailed and washed too, and they will pick apart a newly detailed car in the SC then ... DOH.

 

[DukeofURL]

I spoke with the lead tech at my SC, he said he was aware of the problem, had a few cars on a list waiting for the fix, and could hear it in my car, but said they don't have an official fix as of yet on the east coast. He also said he offers to replace the air shocks "to keep people happy", but I told him I didn't want to waste others' time and money on something that wouldn't resolve it, and could wait. He did say that on a few occasions the way that owners coordinate online has brought information to him faster than Tesla has sent it internally before, so he'd check into it, but it may be rolling out from east to west coast (not unlike the Model 3 rollout).

As mentioned in a few other posts, I'm happy that Tesla is owning up to it, even if it is taking them a while. I've been on various car forums, and there's always a handful of well-known issues that the manufacturer just turns a blind eye towards. "Cannot reproduce" is the catchall phrase that lets them off the hook.

 

[SuisseDriver]

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)​

Hello, do someone else can confirm that this fix is permanent one and finally solved the issue?
Because if it is the single case and it is just solving the problem for a little time, after what it reappears, I will not push my SC to have it fixed but it really annoys me a lot as my S75D has been making more and more of this noise since almost a year that I have it...

Thanks for anyone to corrobore with their experience if any.

 

[MP3Mike]

Hello, do someone else can confirm that this fix is permanent one and finally solved the issue?
Because if it is the single case and it is just solving the problem for a little time, after what it reappears, I will not push my SC to have it fixed but it really annoys me a lot as my S75D has been making more and more of this noise since almost a year that I have it...

Thanks for anyone to corrobore with their experience if any.

I don't think anyone has had the fix for a long enough period of time to determine that it is permanent.

 

[Joelgjr]

Do you use R19 or R21 rims?

19

 

[Joelgjr]

I spoke with the lead tech at my SC, he said he was aware of the problem, had a few cars on a list waiting for the fix, and could hear it in my car, but said they don't have an official fix as of yet on the east coast. He also said he offers to replace the air shocks "to keep people happy", but I told him I didn't want to waste others' time and money on something that wouldn't resolve it, and could wait. He did say that on a few occasions the way that owners coordinate online has brought information to him faster than Tesla has sent it internally before, so he'd check into it, but it may be rolling out from east to west coast (not unlike the Model 3 rollout).

As mentioned in a few other posts, I'm happy that Tesla is owning up to it, even if it is taking them a while. I've been on various car forums, and there's always a handful of well-known issues that the manufacturer just turns a blind eye towards. "Cannot reproduce" is the catchall phrase that lets them off the hook.

I’m on the east coast and definitely this is THE fix

Waiting for invoice

 

[Dragetreneren]

I spoke with the lead tech at my SC, he said he was aware of the problem, had a few cars on a list waiting for the fix, and could hear it in my car, but said they don't have an official fix as of yet on the east coast. He also said he offers to replace the air shocks "to keep people happy", but I told him I didn't want to waste others' time and money on something that wouldn't resolve it, and could wait. He did say that on a few occasions the way that owners coordinate online has brought information to him faster than Tesla has sent it internally before, so he'd check into it, but it may be rolling out from east to west coast (not unlike the Model 3 rollout).

As mentioned in a few other posts, I'm happy that Tesla is owning up to it, even if it is taking them a while. I've been on various car forums, and there's always a handful of well-known issues that the manufacturer just turns a blind eye towards. "Cannot reproduce" is the catchall phrase that lets them off the hook.

There is no way it is possible to ignore this issue. This is a reproducable issue by owners in 14 countries. While I agree it is good that Tesla is making a progress it has already taken too long. While, in theory, this may be an easy fix given suspension systems are well studied and there are no scientific challenges, only engineering. In practice, this suspension "feature" is not normal and it has taken long time without an official solution which makes it a serious problem implying an unforseen risk for the owners. Already few owners where forced to appeal to legal council, and have defended themselves from this. This is an unnecessary situation and nobody wants this, but for the reasons only Tesla can explain precisely the manufacturer chose to take this legal expense.

 

[Sdub01]

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!

Very similar experience for me. After months of back and forth and frustration, I was offered the 21-inch rim temporary solution and agreed to it but Tesla never followed through.

I was one of the first to get the “permanent fix” (same part number). I quickly realized that it only lessened the clunk/rattle but did not eliminate it. I’d say it is in the neighborhood of 50% better. Not good enough. I was very vocal about my displeasure in the fix not working and was assured it would get back to the engineers. So, I find the engineer’s statement that no one else has complained about the permanent fix dubious—either he’s lying or uninformed.

I took it back in over a week ago. Yesterday I received a message from the service rep stating, “At this current time there isn’t much more we can do.” They have refused to either replace the car or refund my purchase. I’m so fed up at this point and don’t know what else to do. Arbitration? Take a week off work and walk back and forth in front of the dealership with a sign that says “Tesla sold me a clunker and can’t fix it”?

 

[Dragetreneren]

Very similar experience for me. After months of back and forth and frustration, I was offered the 21-inch rim temporary solution and agreed to it but Tesla never followed through.

I was one of the first to get the “permanent fix” (same part number). I quickly realized that it only lessened the clunk/rattle but did not eliminate it. I’d say it is in the neighborhood of 50% better. Not good enough. I was very vocal about my displeasure in the fix not working and was assured it would get back to the engineers. So, I find the engineer’s statement that no one else has complained about the permanent fix dubious—either he’s lying or uninformed.

I took it back in over a week ago. Yesterday I received a message from the service rep stating, “At this current time there isn’t much more we can do.” They have refused to either replace the car or refund my purchase. I’m so fed up at this point and don’t know what else to do. Arbitration? Take a week off work and walk back and forth in front of the dealership with a sign that says “Tesla sold me a clunker and can’t fix it”?

You are certainly not alone. If you didn't know there is a globally accessible questionary: Rattle noise coming from front suspension

Currently there are owners from 14 countries that have reported about their case.


@everybody, @everyone
Feel free to spread the word. It looks like Tesla is still lucking focus on what is important for their customers.. This needs to change.

 

[BillFres]

On Thursday, the Service Center installed new front Air Spring Modules! The rattling noise problem solved, at least for me...

The new part # is 1067361-77-C.

I made them aware of the rattling issue with my car back in the late Spring. They told me they would contact me when there was a fix. I checked in with them in September. I brought the car back in, they checked it, and said there was a fix available. New parts arrived, and are installed.

So far, so good!

 

[mangoesbananas]

Very similar experience for me. After months of back and forth and frustration, I was offered the 21-inch rim temporary solution and agreed to it but Tesla never followed through.

I was one of the first to get the “permanent fix” (same part number). I quickly realized that it only lessened the clunk/rattle but did not eliminate it. I’d say it is in the neighborhood of 50% better. Not good enough. I was very vocal about my displeasure in the fix not working and was assured it would get back to the engineers. So, I find the engineer’s statement that no one else has complained about the permanent fix dubious—either he’s lying or uninformed.

I took it back in over a week ago. Yesterday I received a message from the service rep stating, “At this current time there isn’t much more we can do.” They have refused to either replace the car or refund my purchase. I’m so fed up at this point and don’t know what else to do. Arbitration? Take a week off work and walk back and forth in front of the dealership with a sign that says “Tesla sold me a clunker and can’t fix it”?

Hi there....as I wrote last week, I, too, have not had good results with the “permanent fix”, which was done at Tesla Dublin. I’m curious to know which Tesla Service Center installed your “fix”?

 

[mangoesbananas]

On Thursday, the Service Center installed new front Air Spring Modules! The rattling noise problem solved, at least for me...

The new part # is 1067361-77-C.

I made them aware of the rattling issue with my car back in the late Spring. They told me they would contact me when there was a fix. I checked in with them in September. I brought the car back in, they checked it, and said there was a fix available. New parts arrived, and are installed.

So far, so good!

I’m glad you’re having good results with the “permanent fix”. How long have you been driving since the sex was installed? For me, the rattle started to come back a couple weeks after the “permanent fix”, which was installed at the Tesla Dublin service center. I’m curious to know which service center installed your new modules?

 

[spectrum]

How long have you been driving since the sex was installed?