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Clunk Sound - Dealership Can't Diagnose Yet
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Thread: Clunk Sound - Dealership Can't Diagnose Yet

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    Clunk Sound - Dealership Can't Diagnose Yet

    We have had our 2015 500e for about 14 months. We bought it with 17,000 miles on the odometer and we are now up to about 30,000. About six months ago, we started to hear a clunk sound that is generated in various driving conditions. A variety of things can cause the clunk such as braking into a stop and accelerating from a stop. Turning from the street to enter our driveway pretty reliably produces the clunk. Our driveway is on an uphill and has an s-curb at the street. The clunk does not happen when we drive over the curb with the wheels turned, but instead occurs when straightening the wheels and heading up the driveway. It is as if the combination of turning the wheel and going over the curb makes something shift slightly. Then whatever has shifted slightly moves back into place upon wheel straightening and produces the clunk sound.

    Our local dealer has seen the car twice. First attempt was to change the half-axles. No improvement. Next attempt had two techs using a tool called chassis ears to try to find this sound. The techs have no problem producing the clunk sound on their test drives. So this is not the mystery sound that only the owner hears but does not present itself on test drives for the techs. The techs hear the sound but just can't diagnose where it is coming from. Before our warranty expires in a few weeks, we are going to bring the car to another dealer here in the Phoenix area to see if a different tech with fresh eyes and ears can figure this out.

    Has anybody experienced a similar scenario with the clunking sound? If yes, what was the source of the problem in your case?

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    Quote Originally Posted by my12by60 View Post
    We have had our 2015 500e for about 14 months. We bought it with 17,000 miles on the odometer and we are now up to about 30,000. About six months ago, we started to hear a clunk sound that is generated in various driving conditions. A variety of things can cause the clunk such as braking into a stop and accelerating from a stop. Turning from the street to enter our driveway pretty reliably produces the clunk. Our driveway is on an uphill and has an s-curb at the street. The clunk does not happen when we drive over the curb with the wheels turned, but instead occurs when straightening the wheels and heading up the driveway. It is as if the combination of turning the wheel and going over the curb makes something shift slightly. Then whatever has shifted slightly moves back into place upon wheel straightening and produces the clunk sound.

    Our local dealer has seen the car twice. First attempt was to change the half-axles. No improvement. Next attempt had two techs using a tool called chassis ears to try to find this sound. The techs have no problem producing the clunk sound on their test drives. So this is not the mystery sound that only the owner hears but does not present itself on test drives for the techs. The techs hear the sound but just can't diagnose where it is coming from. Before our warranty expires in a few weeks, we are going to bring the car to another dealer here in the Phoenix area to see if a different tech with fresh eyes and ears can figure this out.

    Has anybody experienced a similar scenario with the clunking sound? If yes, what was the source of the problem in your case?
    Hi my12by60,

    I'm very sorry to hear of the trouble you are experiencing with your 500e! To clarify, have you already engaged our Customer Care Team regarding your situation? If not, please follow up with me via private message, as I would be happy to escalate a case on your behalf to connect you with a case specialist for an additional layer of assistance as you work with your new dealer. Hope to hear from you soon!

    Mark
    FiatCares

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    Ok, thanks Mark. I sent you a private message.

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    Quote Originally Posted by my12by60 View Post
    Ok, thanks Mark. I sent you a private message.

    Thank you very much for doing so, my12by60! I have just responded, please take a moment to review my message and follow up with me there when you can.

    Mark
    FiatCares

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    I have EXACTLY same thing.
    Not only I can hear it, but also I can feel it on the drivers side floor (more on the foot rest).

    Have them search TSBs for front suspension and steering. Mine (2014 - thanks to FCA for a Good Will repair AFTER warranty!!, FiatCares - points for You guys), being I believe 3rd owner, for sure 2nd in Michigan, had same thing and those two TSBs took care of it.

    Unfortunately, the "feeling" started just coming back. I will need to go back and ask them what is happening. However, the noise, clunk, sometimes more like cracking, is gone.
    2016 KIA Forte5 SX 1.6 T-GDI, A/T (sold - CARMAX now has it)
    2014 FIAT 500e
    2016 FIAT 500X Trekking Plus AWD with Roof and Beats
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    Quote Originally Posted by PLP View Post
    I have EXACTLY same thing.
    Not only I can hear it, but also I can feel it on the drivers side floor (more on the foot rest).

    Have them search TSBs for front suspension and steering. Mine (2014 - thanks to FCA for a Good Will repair AFTER warranty!!, FiatCares - points for You guys), being I believe 3rd owner, for sure 2nd in Michigan, had same thing and those two TSBs took care of it.

    Unfortunately, the "feeling" started just coming back. I will need to go back and ask them what is happening. However, the noise, clunk, sometimes more like cracking, is gone.
    Thanks, PLP. We have our 500e back at the dealership right now. Do you happen to have the specific TSB numbers or can you tell us the specific parts that were replaced on your service order that solved your clunk sound?

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    There is a clunk in the steering shaft that is well known and widely reported (multiple threads on this forum), but it would be surprising if the dealer didn't already check it.
    https://static.oemdtc.com/TSB/19-002-15.pdf
    http://www.fiat500usa.com/2015/06/fi...clunk-fix.html

    For those past warranty, people have reported success spraying white lithium grease on the shaft.
    http://www.fiat500usaforum.com/showt...Steering-clunk

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    Yes, thanks. I have already read about the intermediate steering shaft clunk that is common on the cars. That part is inside the cabin of the car and right at the feet of the driver. The clunk sound we are trying to diagnose is clearly coming from outside of the cabin and is much louder than the sound produced by the steering shaft.

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    I got two TSBs:
    TSB 19 002 15 (intermediate shaft)
    TSB 02 006 14 (front jounce bumper)

    Right now the noise is not there, but the feeling is.
    It sounds weird, but again - I do not hear it, I just feel like something is "jumping", kind of like a bolt was loose and was coming out only to then suddenly jump back into place. It happens when turning wheels (either way) especially when slowly going up incline in reverse. Going forward - not really.
    2016 KIA Forte5 SX 1.6 T-GDI, A/T (sold - CARMAX now has it)
    2014 FIAT 500e
    2016 FIAT 500X Trekking Plus AWD with Roof and Beats
    2016 Audi Q5 Premium

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    Quote Originally Posted by PLP View Post
    I got two TSBs:
    TSB 19 002 15 (intermediate shaft)
    TSB 02 006 14 (front jounce bumper)

    Right now the noise is not there, but the feeling is.
    It sounds weird, but again - I do not hear it, I just feel like something is "jumping", kind of like a bolt was loose and was coming out only to then suddenly jump back into place. It happens when turning wheels (either way) especially when slowly going up incline in reverse. Going forward - not really.
    Might be worth taking a look at your floor mats. If you have non factory floor floor mats that don't have the floor hooks or if they are too long, they may have slid inwards which could impede the intermediate shaft from turning properly.

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