2024 TESLA CYBERTRUCK Structure Problems

At approximately 6:30 PM on January 4, I experienced an incident where the passenger front door unlatched, completely by itself without pressing the unlatched button or pulling the manual release. It has since opened itself again in my driveway. And this can be a very serious issue if it worked to unlatch while driving and the door swings open and causes an accident or hits an object or person which can in terms caused serious injury, or property damage, and even in some cases if a passenger is in the seat in the door and latches without their seatbelt on, it can cause serious injury, and or death. In the event of a passenger falling out.

The contact owns a 2024 Tesla Cybertruck. The contact stated that while driving at a moderate speed on a windy day, a metal piece, approximately 2-3 ft. long and located on the side of the sunroof, detached from the vehicle. The contact managed to recover the piece that detached from the vehicle. The vehicle was taken to a Tesla service center, where the failure was acknowledged the failure, and the contact was provided an estimate for the repair. The contact stated that the failure was a manufacturer's defect and that the repair should be free of charge. The vehicle had yet to be repaired. The failure mileage was approximately 11,000.

Mileage: 11,000

On [XXX], [XXX] sat in the left rear-seat of a Cybertruck that was involved in a solo-vehicle collision. [XXX]'s impact injuries were minor. The truck caught fire. The right rear door remained mechanically openable, but its ordinary operation depended on low-voltage electronic buttons located inside the cabin and on the exterior pillar. Those buttons failed after the crash. A man tried to rescue the occupants, but he could not open the doors because the buttons failed and the truck lacks exterior handles. The "armor" glass made it difficult for the rescuer to break open the windows. The mechanical backup releases for the rear doors are concealed beneath the map pocket liner at the bottom of the doors — not feasible to find or use in the smoke, heat and chaos of a post-crash fire. This obscure release left the rear seat occupants with no practical means of egress. [XXX] died of smoke inhalation and burn injuries because he was trapped inside the Cybertruck. Another occupant and the driver also died. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact leased a 2024 Tesla Cybertruck. The contact stated while driving 25 MPH, the windshield wipers turned off. The contact stated that the indicator was inoperable. While depressing the left turn signal, the blinker was slow to respond. While driving on a narrow street, the vehicle swerved to the right. There were no warning lights illuminated. The contact received a recall letter related to NHTSA Campaign Number: 25V170000 (Structure). The vehicle was taken to an independent mechanic who referred the contact to the dealer. The contact called an unknown dealer in Las Vegas, NV, but the vehicle was not diagnosed or repaired. The manufacturer was called, but there was no response for two hours. The contact eventually spoke to a representative who suggested that a service appointment should be scheduled using the App. The failure mileage was approximately 5,000.

Mileage: 5,000

Subject: Tesla Cybertruck Recall – Out-of-Pocket Wrap Costs I own a Tesla Cybertruck (VIN: [XXX] ) affected by the recall on Cant Rail Assemblies. Tesla requires the replacement and welding of new assemblies. My truck is custom wrapped by Rogue Films, a Tesla-recommended supplier. Rogue Films quoted $850 to re-wrap the affected areas after the recall repair. Tesla is only offering $300, leaving me to cover the remaining $550. This cost is a direct result of Tesla’s recall, not elective customization. In addition, Tesla does not provide a loaner vehicle during the lengthy repair process, adding further burden. I am filing this complaint because customers should not have to pay out-of-pocket expenses to remedy a manufacturer’s defect under recall. This is a clear case of recall cost shifting to the end customer. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2024 Tesla Cybertruck. The contact received notification of NHTSA Campaign Number: 25V170000 (STRUCTURE); however, the part to do the recall repair was not yet available. The local dealer was contacted, and it was confirmed that the part was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

The contact owns a 2024 Tesla Cybertruck. The contact received notification of NHTSA Campaign Number: 25V170000 (Structure); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated while driving approximately 15 MPH, the bar off-road light located on the top of the windshield detached from the vehicle. The vehicle was taken to the dealer, who repaired the bar light with an adhesive. The contact stated that after the repair was completed, both sides of the light started to detach. The dealer informed the contact that parts for the recall repair was not yet available. The manufacturer was informed of the failure regarding the bar light and opened a case regarding the failure. The failure mileage was approximately 6,000. Parts distribution disconnect.

Mileage: 6,000

The contact owns a 2024 Tesla Cybertruck. The contact received notification of NHTSA Campaign Number: 25V170000 (STRUCTURE); however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

The contact owns a 2024 Tesla Cybertruck. The contact received notification of NHTSA Campaign Number: 25V170000 (STRUCTURE); however, the part to do the recall repair was not yet available. The local dealer was contacted and refused to repair the vehicle. The dealer informed the contact that the VIN was not under recall. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. In addition, the contact stated the front bumper protector had detached. The vehicle was not diagnosed or repaired after the most recent failure. The failure mileage was unavailable. Parts distribution disconnect.

The contact owns a 2024 Tesla Cybertruck. The contact received notification of NHTSA Campaign Number:  25V170000(Structure); however, the part to do the repair was not yet available. The local Tesla service center was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

The contact owns a 2024 Tesla Cyber Truck. The contact received notification of NHTSA Campaign Number: 25V170000 (Structure); however, the part to do the recall repair was not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

The contact owns a 2024 Tesla Cybertruck. The contact received notification of NHTSA Campaign Number: 25V170000 (Structure); however, the part to do the recall repair was not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

The contact owns a 2024 Tesla Cybertruck. The contact received notification of NHTSA Campaign Number: 25V170000 (Structure); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

Manufacturer is failing to replace the cantrail

The contact owns a 2024 Tesla Cybertruck. The contact received notification of NHTSA Campaign Number: 25V170000 (Structure); however, the part to do the recall repair was unavailable. The dealer was contacted and made aware of the issue; however, the contact was informed that the recall information was not available on the Tesla App. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

This is a supplemental update to Complaint #11656525 regarding NHTSA Recall 25V170 for my 2024 Tesla Cybertruck (VIN: [XXX] ). On [XXX], Tesla returned my vehicle after performing the recall repair. However, the results are visibly flawed on both sides of the vehicle. One side of the cant rail panel overlaps and is misaligned, while the opposite side is spaced too far apart, leaving a visible gap. The right-side gasket was not seated and required me to manually push it back into place. When I raised concerns, Tesla acknowledged that the misalignment exceeds their own internal tolerance threshold, and I was told that it was due to engineering limitations with the replacement parts. They also indicated I may need to return for new parts once a proper fix is available — implying the current repair may not be final or sufficient. This leaves me driving a vehicle that, in my view, remains structurally compromised, potentially vulnerable to panel instability, water intrusion, or corrosion — especially given Colorado’s weather and road conditions. The original recall involved panels detaching while driving. This level of misfitment does not inspire confidence in the safety or durability of the so-called remedy. Wait to schedule another appointment for another reinstall. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2024 Tesla Cyber Truck. The contact received notification of NHTSA Campaign Number: 25V170000 (STRUCTURE) and the local dealer was contacted and refused to replace the cant rail assembly as stated in the recall. The contact was informed that the cant rail assembly had not exhibited delamination and separation from the body of the vehicle to warrant the replacement. The manufacturer was notified of the issue. The contact stated that the rear body panel was not completely secured to the body of the vehicle and was replaced by the dealer. The failure mileage was 6,000. Parts distribution disconnect.

Mileage: 6,000

I am reporting a safety defect on my 2024 Tesla Cybertruck related to Recall 25V170 (cant rail panel detachment hazard). Tesla has confirmed in writing that no remedy is available for my VIN, and they canceled my scheduled service appointment due to this. I explicitly requested that my appointment not be canceled because I felt unsafe driving the vehicle. I also disclosed my safety concerns to Tesla, explaining that this is my primary mode of transportation. Despite my follow-ups, Tesla provided no timeline for repair, leaving me without a safe vehicle. This recall involves a structural panel that may detach while driving, creating a serious road hazard and risk of injury to me and others. Tesla’s inability to fix or address this defect in a timely manner violates federal recall law (49 U.S.C. § 30120(c)). I request that NHTSA investigate this issue and ensure Tesla provides a timely remedy or refund.

At highway speeds (typically between 70–80 mph), the driver’s side door of my Tesla Cybertruck begins to visibly vibrate and emit wind noise. The vibration is strong enough that I can see the door flexing from inside the cabin. It is not subtle — it shakes to the point that I’ve become genuinely concerned for my safety. At times, it feels unstable enough that I worry the door could detach, which could lead to a serious accident or even death. It is scary, and no vehicle should behave this way at normal highway speeds. I have returned to the Tesla service center seven times for this issue. During my most recent visit, a technician was finally able to reproduce and confirm the problem. I greatly appreciate that the local manager is now taking it seriously, but up until this point, I’ve repeatedly been told “it’s normal,” which it absolutely is not. From what I’ve gathered online, many other Cybertruck owners have reported similar experiences. Some mention a service bulletin and a bracket fix, but I have not received a definitive solution despite the repeated visits. No warning lights or system messages appear when this happens, and the issue only occurs at high speeds. This vehicle has been inspected numerous times by Tesla technicians, but the vibration remains unresolved. I’m reporting this because I believe it reflects a design or manufacturing defect, and I’m deeply concerned about the safety implications if this issue is not addressed.

The contact owns a 2024 Tesla Cybertruck. The contact stated that while driving 80 MPH, the rear driver's side quarter panel trim detached. The contact stated that approximately three days later, the contact became aware that the passenger’s side quarter panel trim had detached. The vehicle was taken to the dealer, who diagnosed a failure with the exterior panel adhesive. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 25V170000 (Structure). The VIN was included, parts were available, but the vehicle had not been repaired. The manufacturer was notified of the failure, and a case was opened. The failure mileage was 22,000.

Mileage: 22,000

The contact owns a 2024 Tesla Cybertruck. The contact stated that while inspecting the vehicle, the contact discovered that the driver’s side, nine-foot-long stainless steel trim piece located above the doors had become loosened and was not completely secured to the frame of the vehicle. The contact reported the failure using the Tesla App, and a service appointment was scheduled. The following day, while driving approximately 75 MPH, the trim piece detached from the vehicle onto the freeway. The cause of the failure was not yet determined, and the vehicle was not repaired. The manufacturer and local Tesla Service Center were notified of the failure. The failure mileage was 25,000.

Mileage: 25,000

The stainless steel trim piece above the windows is only attached by glue and comes loose. My front driver side came detached and the rear came loose on both sides. The piece would have completely fallen off and hit another vehicle if had I not noticed it and re attached it with construction adhesive. There is a whole forum about it on the cybertruck owners club linked below. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

A piece of the stainless steel body trim (right hand roof rail part #1860490-00-C) flew off the car at highway speeds. It looks like it was only held on by glue.

on [XXX], I was driving my cybertruck on highway, at speed 55mph. the stainless panel on driver side, the one, on top of the windows, suddenly start falling off. This is the first winter for cybertruck. the stainless panel is hard and sharp enough to hit other cars. I pulled the car over. Please see my pictures below. Also, i included the youtube link here for your reference. [XXX] This is a serious safety issue. because the body side's stainless panels are glued on the frame with some kind of adhesive, metal to metal, and the nuts hold the frame to the body. Due to the cold temperature and the glued dry up. the stainless panels start falling off. i took a pictures of the new parts to proof that the stainless panel is glued by adhesive to the black frame INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Upper passanger trim piece fell off while driving on street, could have hurt another motorist. When new piece was fixed by Tesla service center, I advised them to replace drivers side just in case and they stated they will not be able to until it falls off. This trim comes in two pieces, one is bolted to the truck and the other is glued onto the bolted piece, the glued piece peeled off. Here is a youtube video showing in more detail the problem. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

We were driving on the freeway yesterday September 3rd at 9:30pm and my passenger side door swung open while on the entrance ramp to highway 24. My infant was sitting in that passenger side in her carseat and thankfully she wasnt injured. A car could have collided with that door or it could have hit anything outside resulting in extreme damage, injury, or death. Upon inspection of the door latch, the door latch is almost completely unhinged. The screw cam off, and the latch simply swivels and does not lock the door or hold it in place. We had to drive home with our hand physically holding the door closed. My driver side door also seems to not be fully latching - though it is not in as bad condition. But upon driving it, you can feel an airgap with the sound at higher speeds which suggests to me that this door latch is also at extreme risk of failure. These two doors are the only ones commonly used by us. But given they are both seemingly failing, my guess is that all four door latches are defective and at immediate risk of causing harm, injury, or death to those Cybertrucks on the road with the same latch.

Brand new car. No accident. The Front and rear passenger doors noted to be misaligned from beginning (with sharp edges). It’s a hazard. Tesla says nothing they can do about it. Unacceptable.

Driving at Approximately 70miles an hour on a divided highway and the top right plastic trim between the back window and the steel side came loose and flew off into traffic behind me creating a road hazard for other motorists. I drove back and picked up the shattered pieces off the highway, no incident was filed with the authorities since there was no accident. I’ve scheduled a service appointment to replace the trim.

Rear trim piece missing clips, flaps in the wind, others have had theirs fly off