Front suspension noise

[Flyingscotsman]

I've had clunking noises from the front of my 2012 Volt since new. When I took the car in for an engine check light, the dealer replaced the drivers side front strut, that fixed the noise. Two weeks later, same noise, now they have replaced the passenger side strut. when I got home from that service visit and was driving slowly into my garage, yes, you guessed, the clunking is back! Has anyone suffered the same problem?
The dealer said there was a new strut design, so was an old design put on, or is there an underlying fault with my particular car?
Either way I'm really unhappy. I've also had to have the charging system tested twice due to the engine check light, which was brought on by two simple power interuptions, one when I tested the "stop" button on my AV 240 V charger, and the other when I pulled the charging cable off just as the charger engaged. "This is normal" acording to GM, really? Any input from anybody, please!
5 problems and 2 weeks in the shop out of just 2 months and 1050 miles, would anybody else say this car is a lemon and ask for a new car or refund?

[Brittt1]

I doubt it qualifies for the lemon law, the lemon law is pretty extensive around allowing a manufacture to fix the same issue multiple times. As for your clunking noise there are definitely low speed suspension noises i hear all the time. As for your check engine light, yes that's normal and has been the subject of some debate where many of us would like these types of errors just as info notices on the main screen. After three drive cycles it will go away. I haven't had one since i learned to correctly remove the charge cable etc.

[quartzav]

Wow, you are really having more issues with clunking sound than normal. From my understanding, the Feb. 9 2012 updated PI0645A bulletin mentioned the new design and advised dealers to wait on replacing the strut assembly. I am also told it is safe to operate the vehicle even when it makes that noise. I plan to wait till the new design comes out before I complain of it again.

[MichaelM]

Things are probably not as bad as they seem.

The front end suspension noise is a known issue, and my (Nov 2012 build) Volt suffered from the same fate. The dealer was most helpful, and immediately replaced both front struts (mid-Jan). Within a day, the noise was back (low speed clunk/rattle, caused by stiction in the struts). SUPER annoying, I know!

Bottom Line: This problem is now well-known on the later 2012 Volts (2011's seem to be fine), and the Cruze is likely affected as well (similar platform, and when the Cruze production was shut down for 2 weeks in November for a "supplier quality problem," the struts were rumored to be the cause. GM is in the process of changing the design / production, etc., but as today there are still bad parts in the system as the new design struts are not yet fully in production.

I was disappointed that the replacement struts were no better than the original ones. So, I raised a very polite, very professional stink at my dealer and asked for their help. They happily sided with me (a low customer-acting-like-a-jerk factor really helps). They contacted GM Engineering and were able to procure a set of revised struts, I believe directly from GM. 500 miles on the new, second replacement set and all is well.

The dealer typically can only replace parts with new service parts from GM, so they did the best they could the first time around and fully expected that would be the end of it.

If you ask your dealer to get into the issue a bit deeper, I'm sure they will find the same information as my dealer did. The issue, as of two weeks ago when my car was finally fixed, was still new enough that there was no officially written communication / service bulletin from GM to the dealers. They really do read those things and take them seriously when they are published.

As for the charging, I'm not the expert that others here are, but I suspect that interrupting the charging, early in the handshaking as you describe, is enough to trip the light. There is a WHOLE BUNCH of hand-shaking and code being executed when charging starts, and if the Volt is not 100% sure why and how it was interrupted, the MIL (Malfunction Indicator Light, ask Check Engine Light) can be tripped. My first MIL was for ice holding the charging door closed; you get two "free" button presses, and if the door doesn't open on the third press, it's MIL-er time!

Way too early to give up -- we're your Volt friends, and we're here to help!

[MichaelM]

Note: My vehicle was repaired JUST before the PI0645A was published. All will be well when the new design is available and your dealer can get the right parts.

[Brittt1]

What is the noise you guys are experiencing? I hear like little popping all around going over rougher roads but considered that normal based on how quiet the cabin was.

[quartzav]

Well, my 2012 had thumping sound on the left front and it was gone after the strut assembly replacement. Now my right front has that noise at low speed over some road irregularities.

[dumluk2002]

Seems like i hear a clunk when i run over certain bumps in the road and only on the left hand side. Trying to figure out if its a problem or just in my head.

[Voltmeister]

Things are probably not as bad as they seem.

Way too early to give up -- we're your Volt friends, and we're here to help!

Well said...Thanks for such a clear and concise helping hand!

[Fulgerite]

My 2012 Volt has almost 4000 miles on it. I have never heard this clunk you describe. I have heard a thunk when I engage or release the parking brake on rare occasions. But that does not bother me at all. You should contact your Volt advisor. If you don't have a volt advisor yet send me a private message and I can put you in touch with one. I am sure GM will be able to solve your problem.

This clunk is a known issue and it CAN be solved. I am sorry you are having an issue.