Dive Brief:
- Tesla recalled around 46,000 Cybertrucks for a condition where stainless steel trim above the side windows can detach from the vehicle while driving, according to the National Highway Traffic Safety Administration.
- The body part, known as a “cant rail”, includes an electrocoated steel stamping with a decorative stainless steel exterior trim cover that’s bonding to it during manufacturing using structural adhesive. Due to insufficient bonding of the adhesive, the steel cover can delaminate and become loose or detach from the vehicle, posing a safety risk.
- The recall covers 2024-2025 Cybertrucks manufactured from November 2023 through February 2025. An estimated 1% of the vehicles may have the defect and the repairs will be covered under warranty. Owners are expected to be notified on May 19.
Dive Insight:
According to the NHTSA recall report, Cybertruck owners also may hear noise inside the cabin, or observe that the cant rail panel is loose or separating from the vehicle if the adhesive bond fails.
Tesla was made aware of the problem on Jan. 7 after the company conducted a routine review of field repairs, which included an investigation of complaints of partial delamination of stainless steel trim pieces on some Cybertrucks.
Following this discovery, Tesla launched an engineering study on Jan. 13 to further investigate the condition, determine the root cause and identify the number of Cybertrucks potentially impacted.
On Jan. 31, Tesla discovered a second stainless steel trim delamination incident on a Cybertruck during another review of field repairs. As a result, the company conducted an engineering study, which included a “pull test” to evaluate the strength of the adhesive bond for the stainless steel cover. Tesla found no signs of metal separation in these tests.
However, the NHTSA’s Office of Defects Investigation notified Tesla on Feb. 21 after it received a vehicle owner questionnaire alleging trim detachment on a Cybertruck. Tesla subsequently reviewed additional complaints of lose trim it identified through social media posts, as well as through service records.
Tesla’s investigation determined that the structural adhesive used to attach the steel trim was susceptible of becoming brittle and losing its bond due to “environmental conditions”, according to the NHTSA. Based on these findings, the automaker decided to voluntarily recall the 46,096 Cybertrucks on March 11.
To address the issue, Tesla will replace the cant rails on the recalled Cybertrucks with an upgraded part using a different adhesive, according to the NHTSA. Tesla will also reinforce the part with a stud welded to the stainless trim that’s secured with a bolt to prevent future detachment.
As of March 14, Tesla identified 151 warranty claims that may be related to the condition. But the electric automaker is not aware of any accidents, fatalities, or injuries due to loose exterior trim.
The Cybertruck recall is Tesla’s third in 2025. In all, up to 677,000 Tesla vehicles could be affected by recalls announced this year, per NHTSA data, including a rearview camera display recall and a recall related to the loss of electronic power steering assist.
