2024 Tesla Cybertruck Body & structure Problems

The contact owns a 2024 Tesla Cybertruck. The contact stated that while driving at an undisclosed speed, the vehicle made an abnormal rattling sound, and the contact noticed that the metal quarter panel was loose. The contact was concerned that the quarter panel detachment could cause a crash. The vehicle was taken to the local dealer, where a replacement quote was provided. The vehicle was not repaired. The manufacturer was contacted and confirmed that there was no coverage. The failure mileage was approximately 3,000.

NHTSA ID

11748520

Incident

Oct 1, 2024

Mileage

3,000 mi

I was driving my Tesla Cybertruck on the highway when I experienced unexpected steering movements from side to side. I attempted to maintain control of the vehicle and slow down. The vehicle ultimately left its intended path and collided with the median. I do not know the cause of the incident. At the time of the accident, I believe a Tesla driver-assistance feature may have been engaged, but I am requesting that Tesla review the vehicle data and logs to determine exactly what systems were active and whether any vehicle malfunction contributed to the event. The accident resulted in significant vehicle damage. I am submitting this report because I am concerned that a potential steering, vehicle control, or driver-assistance system issue may have contributed to the incident and I believe the event should be investigated.

NHTSA ID

11743708

Incident

Jun 8, 2026

The rear passenger side sail applique flew off the truck while I was driving on the freeway.

NHTSA ID

11743041

Incident

May 17, 2026

The vehicle's tonneau cover was defective from the day of delivery and remained unusable for approximately the first 12 months of ownership. Factory over-application of adhesive forced the rear window against the tonneau rollers, preventing operation. I purchased this vehicle specifically for its cargo bed functionality for business use. The cover was finally repaired at Tesla Lincoln, NE when a senior technician was present — root cause identified as a manufacturing defect present from the factory. Component: Tonneau cover / rear bed cover system. Safety: Debris containment failure — unsecured cargo bed.

NHTSA ID

11740934

Incident

Jun 26, 2024

The side sails at the rear of the vehicle, lateral to the bed, are only adhered by double sided tape and can fall off while driving, causing damage to others. This has happened 2 times to my vehicle, it would ah element 3, but we stopped 1 from flying off

NHTSA ID

11721244

Incident

Dec 1, 2025

I have the Foundation Cyberbeast, the model which has an OEM light bar on windshield. While driving on 2-22-2026 at approximately 3:30 pm on the 5 freeway near Santa Ana, the appx 4 ft long light bar flew off and ricocheted violently on vehicle, while still attached by the power cord. This damaged many parts of my vehicle, specifically the glass roof, front windshield, and various body components which were shattered or scratched. I cut my hands. Your database says there are 0 open recalls and that is a lie by Tesla, because they sent me a notice months ago saying they are awaiting mechanical attachment methods. So they know they need to change the attachment method from epoxy to mechanical, but are falsely reporting to the government that they already did so.

NHTSA ID

11719780

Incident

Feb 22, 2026

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.

NHTSA ID

11708700

Incident

Jan 4, 2026

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.

NHTSA ID

11707876

Incident

Dec 30, 2025

Mileage

11,000 mi

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)

NHTSA ID

11694986

Incident

Nov 27, 2024

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.

NHTSA ID

11694114

Incident

Apr 1, 2025

Mileage

5,000 mi

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)

NHTSA ID

11682516

Incident

Aug 18, 2025

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.

NHTSA ID

11673745

Incident

Jul 15, 2025

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.

NHTSA ID

11671773

Incident

Apr 15, 2025

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.

NHTSA ID

11671667

Incident

Jun 5, 2025

Mileage

6,000 mi

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.

NHTSA ID

11669485

Incident

Apr 17, 2025

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.

NHTSA ID

11666639

Incident

Apr 25, 2025

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.

NHTSA ID

11664254

Incident

Jun 2, 2025

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.

NHTSA ID

11663967

Incident

Mar 18, 2025

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.

NHTSA ID

11663163

Incident

May 27, 2025

Manufacturer is failing to replace the cantrail

NHTSA ID

11662018

Incident

May 14, 2025

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.

NHTSA ID

11661134

Incident

May 15, 2025

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)

NHTSA ID

11661066

Incident

May 12, 2025

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.

NHTSA ID

11659426

Incident

May 7, 2025

Mileage

6,000 mi

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.

NHTSA ID

11656525

Incident

Apr 18, 2025

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.

NHTSA ID

11653392

Incident

Jun 1, 2024