2024 Rivian R1S

At 56,083 miles, my 2024 Rivian R1S experienced a suspension warning while driving on the US-101 Freeway and entered reduced-performance/turtle mode, limiting the vehicle to approximately 50 MPH while surrounding traffic was traveling substantially faster. The sudden speed differential created a serious highway collision risk. Rivian inspected the vehicle and diagnosed fault P12DF7A, “Roll Control Cross Circuit Static Leakage Check Failure.” The technician repeated the hydraulic leakage test to rule out a false positive. After draining the hydraulic fluid, Rivian found metal debris throughout the system and documented that it was causing system contamination. Rivian separately confirmed in writing that the source was an “internal mechanical failure in the system.” Rivian Repair Invoice INV_20260811-204135.pdf Rivian determined that the contaminated system required replacement of the hydraulic suspension manifold, hydraulic pump and all four dampers. Its repair procedure requires all four dampers to be replaced when metal debris contaminates the system. Rivian - Metal Debris Email.pdf Critically, Rivian advised me that even if turtle mode did not immediately recur, recurrence was “inevitable in the future” because of the metal debris and stated: “For your safety, we strongly advise against driving the vehicle in this condition prior to completing the full repair.” Rivian - Metal Debris Email.pdf I previously reported excessive suspension clicking to Rivian at approximately 44,000 miles while under warranty. I am aware of at least two potentially similar R1 failures, including another involving reported metal fragments and turtle mode. I request NHTSA investigate whether an internal mechanical failure can introduce metal debris into the interconnected R1 hydraulic suspension system, contaminate multiple components and cause reduced-performance mode at highway speed, and whether similar R1S/R1T incidents indicate a broader safety defect.

Recurring front suspension fastener and component failures causing severe asymmetric inner-shoulder tire wear and steering vibration. Vibration was reported to the manufacturer's service center from delivery (Feb 2024) and repeatedly called "normal." Jan 2025: front left hub bearing and halfshaft replaced under warranty after metal-on-metal grinding. Oct 2025: torn right front lower control arm bushing replaced under warranty; rack measurements before that repair showed front total toe 2.04 deg (spec 0.00-0.40) and rear camber -2.2 deg (spec -0.6 to -1.4); two tires worn to the wear bars on inner ribs were replaced. Mar 2026: vehicle towed in (parking brake would not release, 12v battery failed); technician found front suspension fasteners not torqued to specification, including previously replaced components, and replaced the front left hub a second time. No alignment was performed after the re-torque. Jun 2026: the Oct 2025 tires are again worn to near the wear bars on inner shoulders after ~12,000 miles - the third consecutive set destroyed by the same geometry-driven pattern. The manufacturer has confirmed in writing that only one alignment has ever been performed on this vehicle (Oct 2025) in 26 months and ~41,000 miles - none after the March 2026 suspension re-torque. The manufacturer has two federal recalls acknowledging suspension fasteners loosening after assembly or service: 22V-748 (under-torqued front fasteners that "could cause excessive wheel camber") and 26V003 (rear toe links that may separate), the latter reopened by NHTSA in May 2026 under PE26-004 with review expanded to ~114,922 vehicles. This vehicle exhibits the same failure mode - fasteners confirmed loose by the manufacturer's own technician - but is not in either recall population. Tires worn to the belts and loose suspension hardware at highway speed create a risk of loss of control. Work orders, the alignment report, and photos are available upon request.

On [XXX], I was driving my Rivian R1S on [XXX] in the far left lane at highway speed on a smooth, straight road when I suddenly and completely lost control of the vehicle without warning. The vehicle swerved right, struck a vehicle in the middle lane, then veered left, spun, and collided head-on with the guardrail on the right side of the road. I was evaluated at the scene by EMT. There were no warning lamps, messages, or any symptoms of any kind prior to the failure. The loss of control was instantaneous and without any prior indication of a problem. Review of video footage captured by the vehicle's own cameras clearly shows the rear driver-side toe link failing and the rear wheel moving in a manner inconsistent with normal operation immediately prior to loss of control. At the scene, the rear driver-side wheel was visibly sitting at an abnormal angle, inconsistent with normal alignment, and the toe link bolt was visibly absent from its mounting location. The vehicle is currently being preserved as evidence and is available for inspection. The mounting location where the toe link bolt should be seated is visible and available for examination. The vehicle has not yet been inspected by Rivian, a dealer, or any independent service center. I am aware that Rivian issued NHTSA recall 26V003 on January 8, 2026, covering 2022-2025 R1T and R1S vehicles for this exact defect — rear toe link joint separation while driving, which increases the risk of a crash without prior warning. Rivian acknowledged awareness of at least one prior crash related to this defect prior to the recall filing. My vehicle has no open recalls on record and I was never notified of recall 26V003 or any related service campaign. This incident resulted in a multi-vehicle accident on a public highway. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

clunking/thumping noise coming from front end over speed bumps like something is loose or going to fall apart. have taken car into service few times and was told its normal, its getting worse. Online forum threads have mentioned same issue , I am afraid one of these days something going to snap and cause a breakdown or even worse terrible accident.

Rivian has a 'kneel' option that uses the powered air suspension to lower the vehicle to make entry and exiting the vehicle easier for users. Yes, this can be turned off or on. When on, the function stops if a main door (driver/passenger) is open and left open the car will not continue to kneel for safety purposes. However, it does NOT stop if you are using the rear hatch to access anything. The car continues to kneel. I have hit my head multiple times on the rear hatch because I am behind the vehicle and assume a certain amount of head room and the car is still kneeling and I do not realize it and stand up like I was and hit my head. I have notified Rivian and asked for updates. I consider this a critical issue and has caused minor injury or confusion momentarily. I live on a busy street and the last thing I need is to hit my head and be knocked out. I have not heard anything from Rivian on my request and an update came out to 'fix' items but this was not included. I advised if it was not I would file an official complaint to make them take security and safety issues seriously.