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Picked up R1S 3/31/2024 - broke two blocks later followed by a catastrophic failure

CANCERDOC

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Wanted to share my unlucky delivery experience, and will update this thread as new things happen.

TLDR: R1S PDM broke 2 blocks from the service center after delivery. Reset was performed, was told all is well. Before I even made it home, catastrophic failure on the highway - loud clacking from rear and then BOOM! Felt like I got rear ended on the highway. Rear drive unit major mechanical failure likely due to a malfunctioning disconnect. My R1S which I had driven for less than 1 hour is now in the shop awaiting rear drive unit replacement. I have asked customer service to see if a replacement vehicle can be arranged since it literally failed twice on the same day. A week later and many phone calls, it looks like communication indicates that they are looking into the possibility of a replacement vehicle. Two weeks after going into service, vehicle is repaired. Rivian has agreed to a buyback under the 7 day rule, and that will be credited towards a replacement identical R1S. A refund check has been issued 5/11. Accepted delivery of new R1S on 5/18. Thank you Rivian! New adventures await!


THE LONG VERSION:
I picked up my R1S PDM on 3/31/2024 - the service center was buzzing, many pick ups and the staff were wonderful.

Did the entire vehicle set up, phone key, pairing, etc. I had a grin from ear to ear. What an exciting vehicle. Delivery one week before my birthday. Wow.

3/31/2024:
Two blocks from the Eastvale service center upon accelerating gently from a stop light, I get an "AWD unavailable" and the turtle mode activates. I pull a U turn and take it back. Service tech hops in the car, does a full diagnostic, and tells me the rear disconnect threw an error and they did a diagnostic reset and all appears well. I take it for a 20 min test drive with the delivery guide and test in various modes, and watch how in All Purpose the rear unit engages and disengages. All seems well, no further codes. They tell me "you know with electronics, the first time something happens it can fault out, but once it works, it tends to work well forever." The staff were apologetic, kind and professional. I felt, yeah these are new products, problems can happen, part of being an early adopter. So all is well and I'm off to make the 45 mile drive home where my newly installed Rivian wall charger awaits.

About 40 miles down the road i'm going 65-70 on the highway and accelerate to change lanes. Suddenly a loud rattling/rotational sound emerges from the rear - whirrrrr....clack clack clack clack.....for about 2-3 seconds followed by a huge BANG as if there was an impact in the rear. Instantly I knew there was some horrible catastrophic failure, likely the disconnect failed and might have damaged the rear motor. "AWD unavailable" and turtle mode again. I had power to the front axle and able to maintain highway speeds until I could exit and call service via the Rivian app. They advised me to do a hard reset (left button and hazard), which did not fix the problem. It locked the drive mode and I was not able to switch anything out - drive mode, height, suspension, etc. It did have power to the front axle and despite turtle mode I was able to drive it at highway speeds back to the service center.

Staff were very apologetic, told me they suspected a rear disconnect/rear drive unit catastrophic failure. As it was Easter Sunday, there were no rental or loaner vehicles available. My lovely wife came to pick me up to go home without the Rivian that I had just paid for earlier in the day. I no longer had a grin on my face.

4/1/2024-2:
Service dept now open - they kindly arranged for a UBER ride for me to pick up an R1S loaner. I had to take a half day off from work to make it there before closing time. Upon arrival at the service center, the advisor was professional and tells me they will work on getting authorization for the rear drive unit to be replaced.

On the same day, I contact my guide to ask about my options. The vehicle literally failed the first time two blocks from the service center. Then again 40 miles down the road. And it wasn't a software error. It was a major hardware fault and it was terrifying to experience - literally felt like being rear ended on the highway. I asked whether the vehicle qualified for the 7 day return policy and was told I would lose my deposit if I chose to exercise that option. I actually still want a Rivian and found one in the shop with identical configuration. I asked if a replacement is an option, and I would even be flexible regarding color and options. The guide said a replacement is not an option if the vehicle can be repaired. I asked for the case to be reviewed again, as the vehicle literally broke 2 blocks from the service center - its like a vehicle breaking during a test drive - feels kind of wrong to force the customer to purchase that vehicle. I am awaiting a reply and ideally would like a final answer prior to the 7 day time lapse.

4/3
I received a call from the service center - they have auth to replace the rear drive unit and anticipated parts arrival on 4/10, so likely out of service for about two weeks. The service center has been nothing but professional.

I want Rivian to do well. The vehicle is fantastic. I was so excited for this car, waiting 2 years for delivery. I've never done anything like this before, and this is my first EV. I realize the majority of customers have had trouble free ownership experiences. However, the unpleasant Day 1 event really sours the Rivian experience for me.

4/4
Received voicemail from service - rear drive unit on order, and they will let me know when they receive it and can start the work.

4/5
Texted my guide again asking for an update. Also wrote a detailed email to Rivian support. Got the usual "high volume of emails, reply in 48 hours."

4/8
No response or reply. Guide only says "I am waiting to hear from the service center" which again, seems like a placeholder for another non answer. 7 day period has expired and they have given me no options to consider other than accept back a repaired vehicle, whenever that will be ready. Guide wrote back - "our policy is to repair the vehicle."

Got fed up with my guide, called the general number spoke with a rep who was very patient while I explained my situation. He told me he would someone from sales reach out to me to see if I can be matched to a different vehicle.

4/9
No response from Rivian. I called the service number and explained the situation again. They assured me that someone would reach out to me.

4/10
Received call from service center. Rear motor has arrived, pending repairs. I explained that I’d like to investigate an option to exchange the vehicle given that it failed blocks from the service center. Service manager tells me his supervisor will call me back. Meanwhile I get a text back from my guide saying “we will get you a new vehicle.” The supervisor from the service center calls me back and tells me they will repair the vehicle and extend the 7 day trial period. I said well the guide tells me they are working on a replacement now. Supervisor gets back to me and says someone from the guide’s management will reach out to you in 1-2 days.

So maybe the ball is getting rolling again?

4/12:
Texted guide. Four hours later, reply saying "waiting on reply from management." That's the last I hear from the guide. So it seems the decision is pending, not final.

Received call in the afternoon from the service manager - "your car is repaired and ready." I mentioned, I am waiting for an answer from higher up on whether an exchange will be approved. A service center supervisor calls me and advises me to keep the loaner until Monday when hopefully the management team will have a decision.

4/22 -
After multiple discussions with customer service Rivian agreed to a buyback under the 7 day policy and an identical replacement vehicle is being arranged. I have been sent the new VIN for the replacement vehicle. Overall I am glad Rivian came through.

5/11 -
Refund check issued. Delivery of replacement (identical) R1S pending next weekend. Fingers crossed for a different outcome! I'm looking forward to Rivian 2.0

5/18 -
Picked up the new R1S. Thank you Rivian. Adventures await!
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KBabione

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Sorry to hear about your trials and tribulations...Glad to hear that Rivian is responding professionally and that you're looking at only two weeks or so before you're back on the road. You will not be disappointed - the ride is definitely worth the wait. Our R1S is our first EV as well and, once you gain a little confidence taking longer (400 mile +) trips, you'll relax all the time in your car.

Keep us posted!
 

Oldsmobile_Mike

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I'm sorry to hear this. I took delivery of mine on 3/31/2023, so your pickup date really struck home. Mine has been without any significant issues, 8,800 miles so far. Drove around with my delivery specialist for about an hour before heading home. It was my first time driving an EV and I had to go all the way from Richmond to Northern Virginia. Would've probably been terrified if what you described happened on my drive.

Please keep us updated!
 

Redline

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I had some broken trim and fitment issues when I took delivery end of Q3 2023. I sort of expected that. Then when they fixed my vehicle, they forgot to plug in the rear wiper fluid supply line, which then covered my entire rear inside of the vehicle with the lovely pink solution. They did a great job fixing that, but then my drivers door froze shut during the cold spell this Jan.

Once they fixed that, the car has been flawless. The Minneapolis service center is top notch, and they did everything to make sure I was happy.

They'll do you right as well, just have faith. I can't imagine how frustrated you are, but it seems like you have the right attitude. Good luck, let us know what happens.
 

beyondgravity

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OP, that was an awful experience. I do think Rivian should get you a replacement and you shouldn’t lose your deposit. You have a way much better attitude than me. I am chill; but I do hold the people accountable for their action and in this case total ineptitude from Rivian part.

No vehicle should encounter catastrophic failure very first day or first 7 days perhaps. Rivian should own up to it.

We should take care of each other in general and as a good corporate citizen, I sincerely hope Rivian does the right thing in your case.
 

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majorfriend

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Ugh, that sucks.

It will be worth it in the end and a year from now this won't seem like a big deal, but.....it SUCKS right now.

I ended up having to have my rear drive unit replaced after it failed on 3/22/24 (Launch Edition R1T), and picked it up on 4/1 and was rear ended on the way home (not a good a April Fool's joke).

Luckily the damage is minor and the truck is still drivable. I love the truck, but I feel your pain of not being able to have it in your garage.
 

sfvR1S

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Such a disappointment to wait to get the car and then it immediately breaks. Hopefully Rivian will make it right.
 

Electrified Outdoors

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This sucks and what's worse is the yoyo feeling of grinning ear to ear and then the disappointment of a premature failure.

1) allow them to repair. I haven't heard of too many drive unit failures with DM so this most likely happened due to an assembly defect.

2) the return is a good option only if you do not want to stay in a Rivian. You will lose pre price hike pricing and your deposit but will not have the vehicle anymore.

I would let them attempt repair and see how it goes. I've owned two Teslas and I can't tell you the number of drive unit failures I've seen on those shortly after delivery. This type of thing on electric vehicles, while understandably concerning, is not unheard of.
 

Chrisy

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The rear drive unit's clutch is a major failure point in DMs.
I had the exactly same failure on my R1T last year and as I researched at that time there were multiple reports of the same failure since DMs started to roll out.

Good thing is that they fail fairly quickly (within the first 100 miles or so) on freeways.
And there is a high chance it will be replaced with a good unit. And a good unit will last.

Bad thing is that they can only fix it by replacing the whole RDU which is a major cost.
I am wondering if Rivian can refurbish them or they just scrap 'em. Either way it is added cost to them. (Not to mention the damage made in the customer's perception of the brand)

These 0mile kind of issues are the worse for any OEM.
I would have expected an OEM already fix such a major failure point with an inhouse developed and manufactured part. It is a big shame on Rivian's aftermarket and QA departments in my eyes :no:
 

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I am wondering if Rivian can refurbish them or they just scrap 'em. Either way it is added cost to them. (Not to mention the damage made in the customer's perception of the brand)
Easier to just have the service department swap the RDU and do the refurbishing and testing elsewhere. ICE Engines typically get the same treatment at a dealership, it's rare that they'll tear them down to replace individual internal components.
 

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Chrisy

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Easier to just have the service department swap the RDU and do the refurbishing and testing elsewhere. ICE Engines typically get the same treatment at a dealership, it's rare that they'll tear them down to replace individual internal components.
Yes, I was not clear on that part. I was not expecting Rivian service to refurbish a complex unit like that. They are working on the clock so swapping is what is the most efficient.

I was wondering if the clutch is supplied to them (most probably) and in that case would/could they ask for reimbursement for the failed units.

I work for a major supplier and I know there are negotiations how much we reimburse if whole units fail due to our supplied parts. But I also know calculations are done to see if the cost of the fix/redesign is higher then the (failure rate x reimbursed cost). It might be decided to let it roll with the added "fix cost" until our part will be refreshed anyhow as per the original MY development plan.
Again the later would make sense from money-wise but not good the either of OEM-supplier relations neither for OEM-Customer relations...

But failure rate is not everything, failure severity is also important.
 
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RKRivian

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Had a similar experience., picked up my R1S on Dec 26, 2023 went for a test drive with my guide and the driver side front wheel half saft was not properly connected at the factor, missed final inspection at the factor and at the Toronto Service Center. The half shaft spline was damaged and had to be replace. Not very comforting as you wonder what else might be damaged

The service center was amazing, gave me a loner (we live 50 miles from the SC) fixed the issue and was able to pick up the vehicle 2 days later.

SC Staff was amazing, provided me with photo's of the damage and what was replaced. I was concerned for the first two three weeks following as to what else might go wrong.

I can say after 5,000 miles the vehicle has been flawless, I have not had another issue and really pleased with the vehicle.

Trusting Rivian will resolve the issue and make it right for you.
 

VegasWeezy

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OP, that was an awful experience. I do think Rivian should get you a replacement and you shouldn’t lose your deposit. You have a way much better attitude than me. I am chill; but I do hold the people accountable for their action and in this case total ineptitude from Rivian part.

No vehicle should encounter catastrophic failure very first day or first 7 days perhaps. Rivian should own up to it.

We should take care of each other in general and as a good corporate citizen, I sincerely hope Rivian does the right thing in your case.
Completely agree. I can understand Rivian not wanting to do a replacement or swap to another vehicle in the shop, when the current vehicle can be repaired. However, for the sake of their customer and their customer’s confidence in the brand, they should allow this swap. Then they can do the repair and list the repaired vehicle as new in the shop once available.

This is a miserable experience for OP, but I hope they get the repair right and that you are again grinning ear to ear every time you get behind the wheel.
 

TigerWuxia

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It is certainly a bad experience with a brand new vehicle, and I would be very unhappy as well if I were in such situation. That being said, I would say you give Rivian another chance to fix the vehicle. My new R1S quad had drive unit fluid leak within 2000 miles and I was not happy but Rivian flatbeded the vehicle into the service center and fixed it in 2 days. Although time will tell about long term reliability, I am satisfied with my R1S so far despite the early failure of certain components. Hope this perspective helps.
 

philofilm

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Wanted to share my unlucky delivery experience, and will update this thread as new things happen.

So I picked up my R1S PDM on 3/31/2024 - the service center was buzzing, many pick ups and the staff were wonderful.

Did the entire vehicle set up, phone key, pairing, etc. I had a grin from ear to ear. What an exciting vehicle. Delivery one week before my birthday. Wow.

3/31/2024:
Two blocks from the Eastvale service center upon accelerating gently from a stop light, I get an "AWD unavailable" and the turtle mode activates. I pull a U turn and take it back. Service tech hops in the car, does a full diagnostic, and tells me the rear disconnect threw an error and they did a diagnostic reset and all appears well. I take it for a 20 min test drive with the delivery guide and test in various modes, and watch how in All Purpose the rear unit engages and disengages. All seems well, no further codes. They tell me "you know with electronics, the first time something happens it can fault out, but once it works, it tends to work well forever." The staff were apologetic, kind and professional. I felt, yeah these are new products, problems can happen, part of being an early adopter. So all is well and I'm off to make the 45 mile drive home where my newly installed Rivian wall charger awaits.

About 40 miles down the road i'm going 65-70 on the highway and accelerate to change lanes. Suddenly a loud rattling/rotational sound emerges from the rear - whirrrrr....clack clack clack clack.....for about 2-3 seconds followed by a huge BANG as if there was an impact in the rear. Instantly I knew there was some horrible catastrophic failure, likely the disconnect failed and might have damaged the rear motor. "AWD unavailable" and turtle mode again. I had power to the front axle and able to maintain highway speeds until I could exit and call service via the Rivian app. They advised me to do a hard reset (left button and hazard), which did not fix the problem. It locked the drive mode and I was not able to switch anything out - drive mode, height, suspension, etc. It did have power to the front axle and despite turtle mode I was able to drive it at highway speeds back to the service center.

Staff were very apologetic, told me they suspected a rear disconnect/rear drive unit catastrophic failure. As it was Easter Sunday, there were no rental or loaner vehicles available. My lovely wife came to pick me up to go home without the Rivian that I had just paid for earlier in the day. I no longer had a grin on my face.

4/1/2024-2:
Service dept now open - they kindly arranged for a UBER ride for me to pick up an R1S loaner. I had to take a half day off from work to make it there before closing time. Upon arrival at the service center, the advisor was professional and tells me they will work on getting authorization for the rear drive unit to be replaced.

On the same day, I contact my guide to ask about my options. The vehicle literally failed the first time two blocks from the service center. Then again 40 miles down the road. And it wasn't a software error. It was a major hardware fault and it was terrifying to experience - literally felt like being rear ended on the highway. I asked whether the vehicle qualified for the 7 day return policy and was told I would lose my deposit if I chose to exercise that option. I actually still want a Rivian and found one in the shop with identical configuration. I asked if a replacement is an option, and I would even be flexible regarding color and options. The guide said a replacement is not an option if the vehicle can be repaired. I asked for the case to be reviewed again, as the vehicle literally broke 2 blocks from the service center - its like a vehicle breaking during a test drive - feels kind of wrong to force the customer to purchase that vehicle. I am awaiting a reply and ideally would like a final answer prior to the 7 day time lapse.

4/3
I received a call from the service center - they have auth to replace the rear drive unit and anticipated parts arrival on 4/10, so likely out of service for about two weeks. The service center has been nothing but professional.

I want Rivian to do well. The vehicle is fantastic. I was so excited for this car, waiting 2 years for delivery. I've never done anything like this before, and this is my first EV. I realize the majority of customers have had trouble free ownership experiences. However, the unpleasant Day 1 event really sours the Rivian experience for me.


TLDR: R1S PDM broke 2 blocks from the service center after delivery. Reset was performed, was told all is well. Before I even made it home, catastrophic failure on the highway - loud clacking from rear and then BOOM! Felt like I got rear ended on the highway. Rear drive unit major mechanical failure likely due to a malfunctioning disconnect. My R1S which I had driven for less than 1 hour is now in the shop awaiting rear drive unit replacement. I have asked customer service to see if a replacement vehicle can be arranged since it literally failed twice on the same day. Awaiting reply.
Thanks for posting. This totally blows I think you’re right to ask for a new VIN. And I think it’s wrong to lose your deposit if you change your mind about the purchase in the 7 day window. That ain’t right.
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