how to diagnose and fix my Tesla Model S Original (2012-2020) suspension clunking noise

Tesla Model S Plaid/Refresh (2021-present)

Error Codes

2-4 hours

Time

medium

Difficulty

medium

Severity

3 min read

577 words

Problem Statement

Learn how to diagnose and fix suspension clunking noise in Tesla Model S (2012-2020). Step-by-step guide with diagnostic procedures and repair instructions.

Affected Component

Suspension

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Ensure the vehicle is parked on a flat surface
•Engage the parking brake
•Disconnect the battery if necessary
•Always ensure the vehicle is secure on jack stands before working underneath it

Symptoms

•Clunking noise when driving over bumps or uneven surfaces
•Noise increases when making sharp turns or going over potholes
•Vehicle may feel less stable or have a rough ride
•Creaking sounds when going over speed bumps
•Uneven tire wear

Diagnostic Steps

1
Visual Inspection: Inspect the suspension components (control arms, struts, bushings) for any visible damage or wear.
2
Check for Loose Components: Shake the wheel while lifted to check for play in the suspension parts.
3
Test Drive: Drive the vehicle over various surfaces to replicate the noise and determine the conditions under which it occurs.
4
Listen for Noise: Have an assistant help by listening for the clunking noise while you drive.
5
Inspect Wheel Alignment: Check for misalignment that may contribute to uneven wear or noise.

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•Jack and jack stands
•Socket set
•Torque wrench
•Pry bar
•Creeper

Parts Required

•Control arms (if worn)
•Struts or shocks (if leaking or damaged)
•Bushings (if degraded)

Related Faults

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Diagnostic Steps

1
Visual Inspection: Inspect the suspension components (control arms, struts, bushings) for any visible damage or wear.
2
Check for Loose Components: Shake the wheel while lifted to check for play in the suspension parts.
3
Test Drive: Drive the vehicle over various surfaces to replicate the noise and determine the conditions under which it occurs.
4
Listen for Noise: Have an assistant help by listening for the clunking noise while you drive.
5
Inspect Wheel Alignment: Check for misalignment that may contribute to uneven wear or noise.

Solution

1. Preparation

Tools Required: Jack and jack stands, socket set, torque wrench, pry bar, creeper, and possibly a stethoscope for noise diagnosis.
Safety Warnings: Ensure the vehicle is parked on a flat surface, engage the parking brake, and disconnect the battery if necessary.

2. Raise the Vehicle

Use a jack to lift the front or rear of the vehicle, depending on where the noise is coming from.
Secure the vehicle on jack stands to ensure stability.

3. Inspect and Replace Components

Control Arms:
- Remove the nuts and bolts securing the control arms using a socket set.
- Inspect for cracks or excessive wear. Replace if necessary.
- Reinstall with new components and tighten to manufacturer's torque specifications (usually around 90-100 lb-ft).
Struts or Shocks:
- Detach the top and bottom mounts of the struts/shocks.
- Inspect for leakage or damage. Replace if necessary.
- Install new struts/shocks, ensuring to torque the bolts to specifications (often 35-50 lb-ft for the upper mounts).
Bushings:
- Use a pry bar to check for excessive play in the bushings.
- If worn, remove the old bushings and press in new ones.
- Ensure all bolts are torqued to the manufacturer's specifications.

4. Reassemble and Lower the Vehicle

Reinstall all removed components, ensuring everything is tightened properly.
Lower the vehicle back to the ground and remove the jack stands.

5. Final Checks

Reconnect the battery if it was disconnected.
Clear any fault codes if the vehicle was in a diagnostic mode.