Rear Knock Developed @ 7,000mi

[cpnslow]

Originally Posted by gramicci101

What does "adjusted several weld areas" mean? They rewelded something?

Haha... I was wondering the same thing, and those are the exact words on the invoice. I picked the car up after service hours, so I didn't get to talk in detail with an advisor. Whatever they did, the noise is now gone.

[cpnslow]

Well, 10 days later, and it's back. It was really prominent yesterday when the temperature hit the high 90s. I just dropped off the car again at Stevens Creek Subaru, so I'll update when/what I hear back. I'm starting to like this Forester loaner car they've been giving me, haha.

On the plus side, they're also installing my new OZ Ultraleggera's that I ordered from Tire Rack.

[Halcyon Whisper]

Have that too - Try running with the rear seat down. I believe it is the rear seat latch - have not the time to take apart a rear seat yet <--lazy

[cpnslow]

Originally Posted by Halcyon Whisper

Have that too - Try running with the rear seat down. I believe it is the rear seat latch - have not the time to take apart a rear seat yet <--lazy

I thought that was the issue at the beginning, but this is much louder, and it's definitely coming from the structure. I had all 4 of my new wheels in the car on Thursday when bringing it to the dealership, so the seats were down, and I still had the noise. The service manager is working on the car himself, and asked to keep it for the whole weekend. We'll see what happens...

[cpnslow]

Well, I just picked up the car, and nothing new. I'm gonna drive on it for a few weeks to see what happens.

[Scenic Driver]

Hopefully they used a bigger hammer for the adjustments this time

[cpnslow]

Update! Brought the car back last week... FOURTH time. They still have it and it's been 7 days, by far the longest they've worked on it. I went in today to get an update, and they happened to be working on it when I got there, so I got a look at what they were doing.

Apparently, the anti-corrosive paint that the whole body gets submerged in fills in the gaps between the two welded panels in the rear where the snapping sound is coming from. The combination of the gap and the paint in-between is apparently making this noise. Their solution is to strip back this layer and lubricate the gap. I'm not entirely convinced that excess paint in a gap can create this loud of a sound. However, the amount of work they've been putting into this, hopefully they know what they're doing. I should get the car back tomorrow, hopefully without issue this time. Fingers crossed.