why does my Tesla Model S Original (2012-2020) make a clunking noise when accelerating

Tesla Model S Plaid/Refresh (2021-present)

Error Codes

2-4 hours

Time

medium

Difficulty

medium

Severity

3 min read

495 words

Problem Statement

Learn how to diagnose and fix clunking noise during acceleration 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

•Disconnect the high-voltage battery before working on electrical or drivetrain components.
•Ensure the vehicle is securely elevated and supported on jack stands before working underneath.

Symptoms

•Clunking noise during acceleration
•Noise increases with acceleration intensity
•Possible vibration felt through the cabin
•Unusual sounds when shifting from reverse to drive
•Noise occurs primarily when the vehicle is in motion

Diagnostic Steps

1
Inspect the undercarriage for loose or damaged components.
2
Check the drive axles for signs of wear or damage.
3
Scan the vehicle for any associated error codes using a Tesla diagnostic tool.
4
Examine the suspension components for wear or failure, especially bushings and joints.
5
Test drive the vehicle under controlled conditions to replicate the 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

•Hydraulic jack
•Jack stands
•Socket set
•Torque wrench
•Tesla diagnostic tool (if available)
•Replacement parts as needed (CV joints, axles, bushings)

Parts Required

•Drive axle assembly (if damaged)
•CV joints (if worn)
•Suspension bushings (if deteriorated)

Related Faults

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Diagnostic Steps

1
Inspect the undercarriage for loose or damaged components.
2
Check the drive axles for signs of wear or damage.
3
Scan the vehicle for any associated error codes using a Tesla diagnostic tool.
4
Examine the suspension components for wear or failure, especially bushings and joints.
5
Test drive the vehicle under controlled conditions to replicate the noise.

Solution

1. Preparation

Gather necessary tools and parts.
Park the vehicle on a level surface and set the parking brake.
Disconnect the high-voltage battery to ensure safety.

2. Inspect and Secure Underbody Components

Sub-steps:
1. Lift the vehicle using a hydraulic jack and secure it with jack stands.
2. Visually inspect all underbody components, such as the battery pack brackets, drive unit mounts, and suspension components.
3. Tighten any loose bolts or fasteners found during inspection to manufacturer specifications.

3. Examine Drive Axles and CV Joints

Sub-steps:
1. Remove the front and/or rear wheels as needed.
2. Inspect the drive axles for any signs of damage or excessive play.
3. Check the constant velocity (CV) joints for wear; replace any that show signs of deterioration.
4. If necessary, replace the entire axle assembly.

4. Inspect Suspension Components

Sub-steps:
1. Check suspension bushings, control arms, and strut mounts for signs of wear.
2. Replace any worn components, ensuring proper alignment after replacement.
3. Use a torque wrench to secure all bolts to specified torque values.

5. Reassemble and Test

Sub-steps:
1. Reinstall the wheels and lower the vehicle.
2. Reconnect the high-voltage battery.
3. Perform a test drive to confirm that the clunking noise has been resolved.

Tools Required:

Hydraulic jack
Jack stands
Socket set
Torque wrench
Tesla diagnostic tool (if available)
Replacement parts as needed (CV joints, axles, bushings)

Parts Required:

Drive axle assembly (if damaged)
CV joints (if worn)
Suspension bushings (if deteriorated)

Estimated Repair Time: 2-4 hours

Safety Warnings:

Disconnect the high-voltage battery before working on electrical or drivetrain components.
Ensure the vehicle is securely elevated and supported on jack stands before working underneath.