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

[daktari]

This is the list of work done on mine to try to fix the issue. Still waiting for engineering. I have complained about the same noise.


Visit September
Concern: Customer: noise from front.

Corrections: Link - Sway Bar - Front - Pair
FRONT STABAR LINK - DUAL MOTOR (1030603-00-B) 2.00 0.00 0.00
Replaced Link - Sway Bar - Front - Pair due to possible rot cause.

Corrections: Sensor - Ride Height - Front - LH
AIR SUSP HEIGHT SNSR ASY FR LH (1027941-00-A) 1.00 0.00 0.00
RVT PUSH-PULL 8X18X20.0 (0M1M) (1006521-00-A) 15.00 0.00 0.00
Replaced Sensor - Ride Height - Front - LH due to possible rot cause.

Corrections: Install Front RH Motor Mount Shear Plate
SHEAR PLATE,TRQ RCTN ARM,SDU-F,MDLX (1066608-99-A) 1.00 0.00 0.00
BLT BTNHD M10x1.50x57 [10.9] ZnAl-W (1004350-00-A) 2.00 0.00 0.00
NUT HF M14x1.50 [10] ZnNi NL INSERT (1004358-00-C) 2.00 0.00 0.00
NUT HFPT M14-2.00 [10] ZnNi-W (1004356-00-B) 2.00 0.00 0.00
WASHER SAFETY M24x39 (1020296-00-B) 2.00 0.00 0.00
NUT HF M24x1.5 [8.8] ZnFl-W (1020297-00-A) 2.00 0.00 0.00
Replace Install Front RH Motor Mount Shear Plate due to possible rot cause.

Corrections: Shaft - Steering Column - Intermediate Lower (Dual Motor)
STEERING I-SHAFT LINK LOWER (1060802-00-A) 1.00 0.00 0.00
AIR SUSP RESERVOIR MOUNT ASY W/ FILL VALVE (1013834-00-D)
Replaced Shaft - Steering Column - Intermediate Lower (Dual Motor) due to possible rot cause.

Corrections: Air Suspension System General Diagnosis
Preformed diagnosis.
confirmed customer complaint
we have located the noise and have escalate the case to engineering.
they will keep one working on the finding we have done.

Corrections: Link - Front Suspension - Lower - Aft - LH
FR SUSP AFT LINK ASSY (1048951-00-C) 1.00 0.00 0.00
UPPER CONTROL ARM SUSPENSION ASSEMBLY - FRONT LEFT - DUAL MOTOR (1043965-00-A)
UPPER CONTROL ARM SUSPENSION ASSEMBLY - FRONT RIGHT - DUAL MOTOR (1043966-00-A)
BLT HF M10x1.50x100 [10.9] DP ZnAl-W (1004357-00-A) 4.00 0.00 0.00
NUT, M10x1.50mm (2007059-00-B) 2.00 0.00 0.00
BLT BTNHD M10x1.50x57 [10.9] ZnAl-W (1004350-00-A) 2.00 0.00 0.00
NUT HF M10x1.50 [10] ZnAl-W (1004351-00-A) 2.00 0.00 0.00
Replaced Link - Front Suspension - Lower - Aft - LH due to possible rot cause.

Corrections: Link - Front Suspension - Lower - Aft - RH
FR SUSP AFT LINK ASSY (1048951-00-C) 1.00 0.00 0.00
NUT CLN HEX M14x2.0 [10] ZnAl-W (1006484-00-A) 4.00 0.00 0.00
NUT HF M14x1.50 [10] ZnNi NL INSERT (1004358-00-C) 4.00 0.00 0.00
BOLT H CAM M14x2.00x114 [10.9]-G720 (2007106) 2.00 0.00 0.00
WASHER CAM M14x32x3x2.5 [10]-G720 (2007107) 2.00 0.00 0.00
WASHER, NORDLOCK, 15.2x30.7x3.4 (1033093-00-A) 4.00 0.00 0.00
Replaced Link - Front Suspension - Lower - Aft - RH due to possible rot cause.

Corrections: Knuckle - Suspension - Front - RH
FRONT RIGHT SUSPENSION KNUCKLE ASSSEMBLY - DUAL MOTOR (1030606-00-D)
Replaced Knuckle - Suspension - Front - RH due to possible rot cause.

Corrections: Knuckle - Suspension - Front - LH
FRONT LEFT SUSPENSION KNUCKLE ASSSEMBLY - DUAL MOTOR (1030605-00-D)

Visit August
Concern: Creaking / flexing noise coming from frunk area backorder steering rack E revi
Pay Type: Warranty
Corrections: Steering Rack (Dual Motor)
STEERING GEAR, LHD (1060801-00-E) 1.00 0.00 0.00
LARGE STUFFER, OUTER BELT SEAL (1021462-00-B) 2.00 0.00 0.00
WSHR,6.0x18x1.6mm, EPOXY (1016456-00-B) 4.00 0.00 0.00

Corrections: Air Spring Module - Front - LH
AIR SPRING MODULE FR - MS2 DM (1067361-25-C) 1.00 0.00 0.00

Corrections: Air Spring Module - Front - RH
AIR SPRING MODULE FR - MS2 DM (1067361-25-C) 1.00 0.00 0.00

Corrections: Halfshaft Assembly - Front - LH

Corrections: Halfshaft Assembly - Front - RH

Corrections: Sway Bar - Front (Dual Motor)
FRONT LEFT HALFSHAFT - DUAL MOTOR (1030615-00-B) 1.00 0.00 0.00
FRONT RIGHT HALFSHAFT - DUAL MOTOR (1030616-00-B) 1.00 0.00 0.00

Visit June
Concern: Frunk plastic makes noise
Corrections: Perform Validation Test Drive
Confirmed customer complaint.
we found noise from steering rack. we will continue replacing the steering rack.
STEERING GEAR, LHD (1060801-00-D) 1.00 0.00 0.00

Corrections: Steering Rack (Dual Motor)
Replaced steering rack dual motor. this did not help.
we will wait on a new revi steering rack that is coming later.
we have backorder the new revi steering rack. and we will contackt customer when we
got part in stock.

 

[daktari]

I got a clip of my coil suspension car making the noise:

Not sure if the noise in your is similar to mine.

 

[vraev]

I managed to record a video of the sound emanating from the front of my car. It’s most notable at speeds <45 mph while driving on roads that are not absolutely smooth. (9/2017 build 90D with Firestone air suspension part # 1067361-25-C).

Yup! That is exactly it. The bane of my driving experience in an otherwise perfectly silent and beautiful car. Lol

 

[jelloslug]

Not sure if the noise in your is similar to mine.

It sounds exactly like all the other videos in real life.

 

[jelloslug]

This is the list of work done on mine to try to fix the issue. Still waiting for engineering. I have complained about the same noise.


Visit September
Concern: Customer: noise from front.

Corrections: Link - Sway Bar - Front - Pair
FRONT STABAR LINK - DUAL MOTOR (1030603-00-B) 2.00 0.00 0.00
Replaced Link - Sway Bar - Front - Pair due to possible rot cause.

Corrections: Sensor - Ride Height - Front - LH
AIR SUSP HEIGHT SNSR ASY FR LH (1027941-00-A) 1.00 0.00 0.00
RVT PUSH-PULL 8X18X20.0 (0M1M) (1006521-00-A) 15.00 0.00 0.00
Replaced Sensor - Ride Height - Front - LH due to possible rot cause.

Corrections: Install Front RH Motor Mount Shear Plate
SHEAR PLATE,TRQ RCTN ARM,SDU-F,MDLX (1066608-99-A) 1.00 0.00 0.00
BLT BTNHD M10x1.50x57 [10.9] ZnAl-W (1004350-00-A) 2.00 0.00 0.00
NUT HF M14x1.50 [10] ZnNi NL INSERT (1004358-00-C) 2.00 0.00 0.00
NUT HFPT M14-2.00 [10] ZnNi-W (1004356-00-B) 2.00 0.00 0.00
WASHER SAFETY M24x39 (1020296-00-B) 2.00 0.00 0.00
NUT HF M24x1.5 [8.8] ZnFl-W (1020297-00-A) 2.00 0.00 0.00
Replace Install Front RH Motor Mount Shear Plate due to possible rot cause.

Corrections: Shaft - Steering Column - Intermediate Lower (Dual Motor)
STEERING I-SHAFT LINK LOWER (1060802-00-A) 1.00 0.00 0.00
AIR SUSP RESERVOIR MOUNT ASY W/ FILL VALVE (1013834-00-D)
Replaced Shaft - Steering Column - Intermediate Lower (Dual Motor) due to possible rot cause.

Corrections: Air Suspension System General Diagnosis
Preformed diagnosis.
confirmed customer complaint
we have located the noise and have escalate the case to engineering.
they will keep one working on the finding we have done.

Corrections: Link - Front Suspension - Lower - Aft - LH
FR SUSP AFT LINK ASSY (1048951-00-C) 1.00 0.00 0.00
UPPER CONTROL ARM SUSPENSION ASSEMBLY - FRONT LEFT - DUAL MOTOR (1043965-00-A)
UPPER CONTROL ARM SUSPENSION ASSEMBLY - FRONT RIGHT - DUAL MOTOR (1043966-00-A)
BLT HF M10x1.50x100 [10.9] DP ZnAl-W (1004357-00-A) 4.00 0.00 0.00
NUT, M10x1.50mm (2007059-00-B) 2.00 0.00 0.00
BLT BTNHD M10x1.50x57 [10.9] ZnAl-W (1004350-00-A) 2.00 0.00 0.00
NUT HF M10x1.50 [10] ZnAl-W (1004351-00-A) 2.00 0.00 0.00
Replaced Link - Front Suspension - Lower - Aft - LH due to possible rot cause.

Corrections: Link - Front Suspension - Lower - Aft - RH
FR SUSP AFT LINK ASSY (1048951-00-C) 1.00 0.00 0.00
NUT CLN HEX M14x2.0 [10] ZnAl-W (1006484-00-A) 4.00 0.00 0.00
NUT HF M14x1.50 [10] ZnNi NL INSERT (1004358-00-C) 4.00 0.00 0.00
BOLT H CAM M14x2.00x114 [10.9]-G720 (2007106) 2.00 0.00 0.00
WASHER CAM M14x32x3x2.5 [10]-G720 (2007107) 2.00 0.00 0.00
WASHER, NORDLOCK, 15.2x30.7x3.4 (1033093-00-A) 4.00 0.00 0.00
Replaced Link - Front Suspension - Lower - Aft - RH due to possible rot cause.

Corrections: Knuckle - Suspension - Front - RH
FRONT RIGHT SUSPENSION KNUCKLE ASSSEMBLY - DUAL MOTOR (1030606-00-D)
Replaced Knuckle - Suspension - Front - RH due to possible rot cause.

Corrections: Knuckle - Suspension - Front - LH
FRONT LEFT SUSPENSION KNUCKLE ASSSEMBLY - DUAL MOTOR (1030605-00-D)

Visit August
Concern: Creaking / flexing noise coming from frunk area backorder steering rack E revi
Pay Type: Warranty
Corrections: Steering Rack (Dual Motor)
STEERING GEAR, LHD (1060801-00-E) 1.00 0.00 0.00
LARGE STUFFER, OUTER BELT SEAL (1021462-00-B) 2.00 0.00 0.00
WSHR,6.0x18x1.6mm, EPOXY (1016456-00-B) 4.00 0.00 0.00

Corrections: Air Spring Module - Front - LH
AIR SPRING MODULE FR - MS2 DM (1067361-25-C) 1.00 0.00 0.00

Corrections: Air Spring Module - Front - RH
AIR SPRING MODULE FR - MS2 DM (1067361-25-C) 1.00 0.00 0.00

Corrections: Halfshaft Assembly - Front - LH

Corrections: Halfshaft Assembly - Front - RH

Corrections: Sway Bar - Front (Dual Motor)
FRONT LEFT HALFSHAFT - DUAL MOTOR (1030615-00-B) 1.00 0.00 0.00
FRONT RIGHT HALFSHAFT - DUAL MOTOR (1030616-00-B) 1.00 0.00 0.00

Visit June
Concern: Frunk plastic makes noise
Corrections: Perform Validation Test Drive
Confirmed customer complaint.
we found noise from steering rack. we will continue replacing the steering rack.
STEERING GEAR, LHD (1060801-00-D) 1.00 0.00 0.00

Corrections: Steering Rack (Dual Motor)
Replaced steering rack dual motor. this did not help.
we will wait on a new revi steering rack that is coming later.
we have backorder the new revi steering rack. and we will contackt customer when we
got part in stock.

When those items were replaced, did the noise change at all? My steering rack was replaced as an attempt to correct the noise and it changed a bit and was somewhat quieter for a while but now it's just as loud as it ever was.

 

[Julie's MS]

Have there been any updates or changes with the suspension since 2016? I wish there was a way to track updates and changes to the car. Apart from the obvious ones. I must agree the suspension could do with an over haul or update. Surely Tesla has learned some things over the years and can offer a better suspension. More durable and firm for cornering etc.

 

[kmob07]

I had the exact same noise as posted in the most recent video, only audible at low speed (but VERY loud, particularly outide the car). I just got it back from the shop today and I can confirm that they fixed it (at least as far as my 20 minute drive home!).

Attached is the relevant part of my repair invoice - I have a February '17 build 90D with air suspension.

 

[daktari]

Yes, but it quick

When those items were replaced, did the noise change at all? My steering rack was replaced as an attempt to correct the noise and it changed a bit and was somewhat quieter for a while but now it's just as loud as it ever was.

Yes but it came back. I also got a huge clunk in speedbumps for a few months after the last repair. Now, with softer winter tires and a retrofitted HEPA-filter it is not to low but still there. Sometimes suspension feels softer, sometimes stiff, like a locked out damper on a mountain bike. More sound in the last scenario.

 

[CaliSol]

I had the exact same noise as posted in the most recent video, only audible at low speed (but VERY loud, particularly outide the car). I just got it back from the shop today and I can confirm that they fixed it (at least as far as my 20 minute drive home!).

Attached is the relevant part of my repair invoice - I have a February '17 build 90D with air suspension.

View attachment 292116

Hi kmob07,

I’m reconciling the part numbers you got replaced with daktari’s exhaustive list of replaced parts. It appears that daktari’s SC had replaced the same exact three parts as you. The difference is that daktari’s car still has the sound, despite the intervention. I wonder if you truly had the same issue that we’re experiencing.


FR SUSP AFT LINK ASSY (1048951-00-C)
NUT HF M14x1.50 [10] ZnNi NL INSERT (1004358-00-C)
WASHER, NORDLOCK, 15.2x30.7x3.4 (1033093-00-A)

 

[kmob07]

Hi kmob07,

I’m reconciling the part numbers you got replaced with daktari’s exhaustive list of replaced parts. It appears that daktari’s SC had replaced the same exact three parts as you. The difference is that daktari’s car still has the sound, despite the intervention. I wonder if you truly had the same issue that we’re experiencing.


FR SUSP AFT LINK ASSY (1048951-00-C)
NUT HF M14x1.50 [10] ZnNi NL INSERT (1004358-00-C)
WASHER, NORDLOCK, 15.2x30.7x3.4 (1033093-00-A)

Well, to the extent that listening/watching the above YouTube video allows me to diagnose my noise as “the same issue” it is. Of course it’s always possible that it was a different issue. I’m about 250 miles from the repair and no return of the noise yet.

I hope other people are able to get this resolved!

 

[mangoesbananas]

I just picked up a brand new 2018 build 75D Model S on Mar. 26, 2018 in San Francisco. After driving only a few miles, I started hearing a slight rattling noise from the front end of the car. Every day the noise got louder. And now, with only 250 miles on the car, it's at the Dublin Service Center. After they did a test drive and kept the car overnight, they told me that it is an issue with the right front strut/suspension. They made it sound like it's an issue that they're just beginning to be informed about. But, clearly from this forum, the issue is long-standing and widespread. I was told to leave the car there till next week so they can see if a "revision" will come this coming week from engineering. When I asked why they don't just replace the strut, they said it is better to wait for the revision.

Well, if all the people on this thread have been waiting for this "revision" since 2016, I don't hold out a lot of hope. It is beyond my comprehension why a company that prides itself in creating the greatest cars ever made can not come up with a fix for this issue, and that we who have spent around $100G for the privilege of owning a Tesla have to drive around with a car that is known to be faulty.

At what point does the lemon law come into play?

 

[outie]

I just picked up a brand new 2018 build 75D Model S on Mar. 26, 2018 in San Francisco. After driving only a few miles, I started hearing a slight rattling noise from the front end of the car. Every day the noise got louder. And now, with only 250 miles on the car, it's at the Dublin Service Center. After they did a test drive and kept the car overnight, they told me that it is an issue with the right front strut/suspension. They made it sound like it's an issue that they're just beginning to be informed about. But, clearly from this forum, the issue is long-standing and widespread. I was told to leave the car there till next week so they can see if a "revision" will come this coming week from engineering. When I asked why they don't just replace the strut, they said it is better to wait for the revision.

Well, if all the people on this thread have been waiting for this "revision" since 2016, I don't hold out a lot of hope. It is beyond my comprehension why a company that prides itself in creating the greatest cars ever made can not come up with a fix for this issue, and that we who have spent around $100G for the privilege of owning a Tesla have to drive around with a car that is known to be faulty.

At what point does the lemon law come into play?

I just picked up my X 100D last Friday and I also got that same noise and it’s driving me crazy. It’s only apparent at low speed. Please let me know how yours goes next week. I am waiting for more isssues to come up before I bring the car in.

 

[Raechris]

I just picked up a brand new 2018 build 75D Model S on Mar. 26, 2018 in San Francisco. After driving only a few miles, I started hearing a slight rattling noise from the front end of the car. Every day the noise got louder. And now, with only 250 miles on the car, it's at the Dublin Service Center. After they did a test drive and kept the car overnight, they told me that it is an issue with the right front strut/suspension. They made it sound like it's an issue that they're just beginning to be informed about. But, clearly from this forum, the issue is long-standing and widespread. I was told to leave the car there till next week so they can see if a "revision" will come this coming week from engineering. When I asked why they don't just replace the strut, they said it is better to wait for the revision.

Well, if all the people on this thread have been waiting for this "revision" since 2016, I don't hold out a lot of hope. It is beyond my comprehension why a company that prides itself in creating the greatest cars ever made can not come up with a fix for this issue, and that we who have spent around $100G for the privilege of owning a Tesla have to drive around with a car that is known to be faulty.

At what point does the lemon law come into play?

My understanding is that the lemon law is for a significant safety issue that remains unresolved after three repair attempts. So far it does not appear this noise has caused any failures or safety concerns. I have it too and just glad it goes away with speed and/or music volume.

 

[mangoesbananas]

Thanks, Raechris, and I sure hope the strut issue doesn't become a safety issue (if it hasn't already). By the way, you're right that music or driving faster makes the noise inaudible, but having to cover up a rattle in a car by turning up the music or driving faster isn't what I had in mind when I spent nearly $100G for what is billed as the best car ever made. I'm just hoping Tesla will do the right thing...and do it soon.

 

[ILLCOMM]

My understanding is that the lemon law is for a significant safety issue

Until we know the root cause we cannot know that it isn't a significant safety issue. If your suspension fails at speed, well, that's no bueno.

 

[mangoesbananas]

Until we know the root cause we cannot know that it isn't a significant safety issue. If your suspension fails at speed, well, that's no bueno.

EXACTLY!!

 

[Jeroenhermans]

My car is again at the Service center today for this issue (and a few other minor items). I will update you when I get it back with the results.

 

[hroussel]

I have the same rattle problem. A December 2017 model S. Going to the SC on Friday for that (and one squeak in the cabin).

I wonder if we should not create a poll to try and find out how many owners of recent model S (since last April for example) have the problem. Maybe putting "Rattlegate" in the title would stirs things up a bit...

 

[outie]

My car is again at the Service center today for this issue (and a few other minor items). I will update you when I get it back with the results.

Any result?

 

[kcarr0054]

I have the same rattle problem. A December 2017 model S. Going to the SC on Friday for that (and one squeak in the cabin).

I wonder if we should not create a poll to try and find out how many owners of recent model S (since last April for example) have the problem. Maybe putting "Rattlegate" in the title would stirs things up a bit...

Yes to "Rattlegate". Does anyone know if the Model X has this front end rattle? Or do they have different part numbers? Same here Dec 2017 Mod S 75 D Air Suspension