The metal fatigue is real guys. Also this is a real issue. Let me tell you what happened.
I'm in a non-core market zone and my 2017 S90D was never serviced back in 2019. I always heard that rattle/shudder but never made anything out of it. Then in April of 2019 at our drive electric event I was giving test rides in my Tesla to people. I gave maybe 20 test rides with people in all seats, a short 1 mile course in the forest country roads. Doing heavy acceleration for maybe 4-5 seconds on every test. At the last one I heard a very bad sound of something breaking in the front. Turns out, it is the FORELINK ASSY LH. Unbelievable that it broke. (see photo attached) If this happened at highway speeds I could've died. I still can't fathom how Tesla is not taking responsibility for this. Well, turns out the forelinks are indeed a warranty item and they're changing it on every car built prior to mid. 2017 I guess.
So moral of the story, never drive your car with that noise. Also, Tesla definitely needs to find a permanent solution to this.
p.s. I replaced my forelinks (both LH and RH) myself after this. Luckily this happened while going slow so it didn't tear my cowl or other joints in drivetrain. However I still have this noise. My car was just about to cruise past 80k kms (out of warranty) so I drove 1500km in a non-Supercharger zone 4 months ago to the nearest Tesla centre 5 countries away. In my service notes I mentioned this issue.They said they needed to replace some joints, check it and if it does not solve it they need to change the axle. However they don't have said joints in stock and they can't directly change the axle without trying joints first. So they're noting this down and won't leave it out of warranty next time I go. Now my car is approaching 100k kms and I don't know when I can do the 5 country/1500km trip. Definitely not in the winter when you consider 50kW ChaDeMo is all I have for the first 1000km of the trip.