2019 Tesla Model 3 Body & structure Problems

Summary of the Problem Rear subframe assembly and multiple rear suspension links required full replacement due to failure/wear at approximately 51,890 miles, on a vehicle with no history of collision or accident damage. Tesla diagnosed the issue as an interior rattle/squeak reproducible over bumpy roads and speed bumps, which led to replacement of the rear subframe and nearly the entire rear suspension link set. Total repair cost was approximately $7,667.65, entirely out of pocket, as Tesla stated no recall applies to this VIN. Full Description (detailed narrative field) In December 2025, I began noticing a rattling/squeaking noise from the rear of my 2019 Tesla Model 3, reproducible on bumpy roads, speed bumps, and rail tracks. The vehicle has never been in an accident and has no history of collision damage. I brought the vehicle to Tesla Service (Fremont, CA) on 07-Jan-2026 at 51,890 miles. Tesla's diagnosis found it necessary to replace: The rear subframe assembly Rear toe link assemblies (left and right) Rear upper fore link assemblies (left and right) Rear lower fore link assemblies (left and right) Rear upper aft link assemblies (left and right) Front lower compliance links (left and right) Front lower lateral links (pair) A four-wheel alignment This amounted to nearly a full rear (and partial front) suspension rebuild, at a cost of $6,843.34 for this job alone, and $7,667.65 total, entirely at my expense. Tesla confirmed there is no open recall covering this VIN or this failure. I am concerned this represents a premature structural/suspension component failure unrelated to accident damage or normal wear, at a mileage (51,890) that suggests a potential defect in the subframe or suspension hardware/corrosion resistance for this model year, rather than an isolated wear item. I am filing this complaint so NHTSA can evaluate whether this is part of a broader pattern for 2019 Model 3 vehicles.

NHTSA ID

11748392

Incident

Dec 22, 2025

Component: Exterior Door Handle (Front Passenger) Incident Description: A latent manufacturing defect resulted in the structural delamination of the interior chrome plating on the front passenger door handle. This failure occurred after the last use of the handle, creating a razor-sharp metallic edge that was not visible during a normal approach to the vehicle. Upon contacting the handle to open the door, a passenger sustained a deep laceration from this jagged metallic blade. Safety Hazard: The defect transforms a primary vehicle touchpoint into a concealed cutting hazard. The chrome skin peels and curls into a sharp edge without warning or visible signs of wear, posing an ongoing risk of serious physical injury to any occupant. Manufacturer Response: Tesla Service (Los Gatos) was provided with photographic evidence of the razor edge and the resulting injury. While acknowledging the injury, Tesla refused a safety-based "goodwill" repair, citing the vehicle’s age (2019) and the absence of a formal recall. Tesla further attempted to attribute this structural material failure to cleaning products, despite the vehicle being garage-kept and maintained only with pH-neutral enthusiast-grade soaps. Tesla has since refused further discussion. Request: This defect poses an ongoing risk of serious physical injury to any occupant using the handles. I am reporting this to assist in identifying a trend of material failure in 2017–2020 Model 3 chrome door handles.

NHTSA ID

11737862

Incident

May 12, 2026

The chrome lamination/sticker is peeling from the underside of the door handles. This peeling causes an extremely sharp edge that cut my finger. This issue is noted rather constantly over the internet. The sharp edge is hidden by the retracting mechanism of the door handles, and so you don’t see it until you grab it and cut yourself.

NHTSA ID

11732300

Incident

Apr 18, 2026

The accident happened in a parking lot. There was a tap of the bumpers going really slow. The passenger in the Tesla is claiming whiplash. The car is not safe if it cannot take a slight bump on the fender in a parking lot.

NHTSA ID

11631768

Incident

Nov 19, 2024

On at least 3 occasions, the glass (windshield, roof and rear window) on my car has been shattered by a small nut (beechnut) falling from a tree. The cost of the damage has totaled thousands of dollars. The latest incidents were on July 31 and August 15, 2024. A previous incident occurred a few years ago.

NHTSA ID

11608775

Incident

Aug 15, 2024

My wife was dropping my kid in the school drop off line. The speed was probably about 5 mph. The Tesla suddenly went into a sudden spontaneous acceleration. When my wife tried to brake, the brakes did not work. There was no forward collision warning beeping sound that went off, which is supposed to. It hit the vehicle in front and finally hit a fence. so, both the accelerator and brake malfunctioned. The car will go to a body shop tomorrow. Since it was a school drop off zone, safety of a lot of people were put at risk. It was very hard to get Tesla on the phone. so, we went into a Tesla service center and a complaint was filed. They will be reviewing the data but I dont know how long it will take. A software update had been applied a week back. 2 hours after the accident, a software update screen popped up

NHTSA ID

11522124

Incident

May 12, 2023

I was driving using beta full self driving feature, and the vehicle was involved in a collision

NHTSA ID

11509538

Incident

Feb 28, 2023

2019 TESLA MODEL 3. CONSUMER WRITES IN REGARD TO TRUNK HARNESS SAFETY RECALL. THE CONSUMER REQUESTED INFORMATION REGARDING WHEN THE HARNESS MAY BE AVAILABLE.

NHTSA ID

11484759

Incident

Sep 16, 2022

When heavy down rain falls and the streets start to collect water of 1-2 or more the uderbody skid plates with collect water and the body panels fasteners will fail and the skid plate tears. This has happed twice since I've owned the car. This last time happed last week when a heavy rain came through. I'm now over my warranty but the problem keeps happening. Tesla has a bulletin specifically for this dated September 19, 2019 address this problem. Tesla TSB SB-19-12-00. Tesla service in Austin, TX is denying my car a replacement skid pad since I'm at 55,000 miles, just 5K past my warrenty. Even though they know this part will fail if the car happens to go through enough water from a heavy rain. If this part is not replaced water can then get into the rear bumpers and then cause them to be ripped off which could then cause an accident if this were to happen at hwy speeds.

NHTSA ID

11472797

Incident

Jun 28, 2022

Received an alert through the Tesla App that my car alarm was going off. When I stepped outside my house I saw smoke coming out of the windows. I opened the rear passenger door and saw the floor on fire. I went inside and called the fire department. By the time they arrived the entire car had been destroyed.

NHTSA ID

11464748

Incident

May 14, 2022

Vehicle handle will become frozen and because of the design, it is difficult to open the door. Once it is opened, the windows will not roll down far enough for the driver to close the door. Because of this, the driver will need to move or drive the vehicle with the door open.

NHTSA ID

11454207

Incident

Feb 26, 2022

The casing that the batteries are covered in will sometimes "pop" during charging or preconditioning events. I think it's made from AL and the temperature increase during cold days causes this pop. This may cause high cycle fatigue in colder climates while the vehicle is being charged constantly.

NHTSA ID

11438612

Incident

Oct 17, 2021

In August 2021, I discovered that the glass roof of my car had major cracks even though I had not had a collision and was not aware of any specific cause for such major damage. According to Tesla technicians who examined the damage, the roof glass had "a small crack running in top layer of glass along with a small star crack on the front left"; the back glass had "several cracks all over it with two large impacts"; "both glass pieces showed external damage on both front and rear." As a result, it was necessary to replace the glass, at a cost of over $2000. A hickory tree stands next to the uncovered driveway where the Tesla is normally parked since it was bought over two years ago. I am incredulous that falling hickory nuts might have caused such extensive damage, as Tesla theorized happened. In any case, if the roof glass is so fragile that a few falling hickory nuts could destroy the roof, it seems that the roof is not sufficiently strong and sturdy and could therefore be a safety hazard.

NHTSA ID

11438346

Incident

Jul 21, 2021

PART NUMBER 1131205-00-CC (PP-GF20), POOR DESIGN BREAKS EASY ON (3) THIN TABS UNABLE TO SUPPORT PUSH/PULL OF PANEL TO SEAT GROMMETS, USE TO HOLD UP PANEL IN FRUNK PORTION OF VEHICLE WHERE CLEAN AIR INTAKE. THIS ALLOWS A PANEL TO HOLD THE PUSHING AND PULLING OFF OF A PANEL. ALOT OF PEOPLE ARE UNAWARE THIS PART IS BROKEN, USUALLY STARTS IN MANUFACTURING INSTALLATION.

NHTSA ID

11360690

Incident

Jun 19, 2019

DO TO A LARGE BACK WINDSHIELD (ENTIRE VEHICLE ROOF IS MADE OUT OF CLASS) I BELIEVE THAT THE HEAT MAKES THE WINDSHIELD CRACK. I POSTED A VIDEO ON YOUTUBE EXPLAINING HOW MY VEHICLE WINDSHIELD BROKE DOWN BY THE INTENSE HEAT, A PERSON REPLIED WITH THE SAME PROBLEM. *TR

NHTSA ID

11320507

Incident

Mar 14, 2020

Mileage

13,428 mi

WHEN GET WET, UNDERCARRIAGE COMPOSITE TRY GETS HEAVY WHEN WATER IS ABSORBED AND FALL/ TEAR AND GET DRAGGED ON THE STREET, SOMETIMES RESULTING IN FRICTION SPARKS.

NHTSA ID

11316578

Incident

Mar 4, 2020

Mileage

20,000 mi

AUTOPILOT WAS ENGAGED. THE TESLA VEHICLE SENSORS FAILED TO RECOGNIZE 2 PARKED VEHICLES ON THE RIGHT SIDE OF THE STREET WHILE DRIVING, AND COLLIDED WITH THEM. ANTI-COLLISION MECHANISM AND AUTO-BRAKING FAILED TO APPLY, RESULTING IN COLLISION.

NHTSA ID

11302321

Incident

Jan 17, 2020

Mileage

3,370 mi

THIS INCIDENT HAPPENED BECAUSE OF SUDDEN ACCELERATION ISSUE IN TESLA MODE 3 IN OUR PARKING LOT. I WAS PARKING BETWEEN 2 CARS ON MY RIGHT. SO, WAS REALLY SLOW. WHILE TURNING THERE WAS A SUDDEN ACCELERATION AND THE VEHICLE WAS AT A HIGH SPEED. SINCE, I WAS TURNING, THE CAR ROTATED AT THE HIGH SPEED AND IN THE PROCESS MY CAR HIT CAR ON MY LEFT, 3 CARS ON MY FRONT. THERE WAS SEVERE DAMAGE TO MY CAR AND A FLAT TIRE. FORTUNATELY, NO PEOPLE WERE AFFECTED. WHEN THE ACCIDENT HAPPENED, ALL SYSTEMS STOPPED FUNCTIONING.

NHTSA ID

11300620

Incident

Dec 31, 2019

Mileage

4,000 mi

I AM FEMALE SAFE DRIVER WITH CLEAN DRIVING RECORDS, MY TESLA WAS THIRD CAR STOPPED AT TRAFFIC LIGHT ON DEC 19TH IN THE CITY STREET, AND ALL OF SUDDEN, I STRONGLY BELIEVE THAT IT TRIGGERED UNINTENDED SPONTANEOUS ACCELERATION THAT RESULTED IN ACCIDENT WITH TWO CARS AHEAD OF ME, DAMAGED ALL 3 VEHICLES INCLUDING MINE, I PUSHED THE BRAKE IMMEDIATELY & PARKED BEFORE ALL AIRBAGS IN MY CAR DEPLOYED. I TRIED TO PROVE MY POINT TO THE INSURANCE THAT ITS NOT MY FAULT BUT ITS A CAR THAT BECAME UNCONTROLLABLE DUE TO PROBABLY SOME KIND OF NIGHTLY AUTOMATIC SOFTWARE UPDATE OR A MECHANICAL PROBLEM BUT INSURANCE DIDN'T AGREE AND FORCED ME TO AGREE THAT I DID IT !

NHTSA ID

11300156

Incident

Dec 19, 2019

Mileage

4,361 mi

MY WIFE WAS TRYING TO PARK THE CAR IN OUR GARAGE WHEN THE CAR SUDDENLY SPED UP AND HIT OUR INNER GARAGE WALL. IT THEN REVERSED BACK AND HIT THE WALL A SECOND TIME. THEN IT AUTOMATICALLY REVERSED AND PARKED ON THE NEIGHBOR'S DRIVEWAY. BOTH THE STERLING AIR BAG AND AIRBAG NEAR THE FEET DEPLOYED. THE CAR'S FRONT WAS SMASHED. OUR GARAGE WALL AND DOOR ARE ALSO BADLY DAMAGED. I HAVE ASKED TESLA TO INVESTIGATE IF IT WAS BECAUSE OF THE AUTOPILOT TAKING OVER BUT HAVE NOT RECEIVED A RESPONSE FROM THEM YET AFTER MORE THAN A WEEK.

NHTSA ID

11267131

Incident

Sep 29, 2019

Mileage

7,143 mi

AS I WAS OPENING THE PASSENGER DOOR, MY NAIL GOT CAUGHT IN THE SPACE BETWEEN THE HANDLE AND THE CAR. AS BACKGROUND, IN ORDER TO OPEN THE DOOR ONE I HAS TO PUSH THE HANDLE ON ONE SIDE FOR THE OTHER SIDE TO COME OUT, AS I WAS DOING THIS MY NAIL GOT CAUGHT IN THE GAP CREATED WHEN PUSHING ONE SIDE TEARING OFF MORE THAN HALF OF MY NAIL. THIS ALSO RIPPED THE SKIN AND I HAD TO GO TO THE HOSPITAL WHERE I GOT TWO SHOTS BECAUSE THE PAIN WAS SO INTENSIVE, AND THEN I NEEDED WRAPPING AND A SPLINT.

NHTSA ID

11252811

Incident

Aug 31, 2019

TESLA MODEL 3 THE MID AERO SHIELD WAS DAMAGED WHILE DRIVING IN THE RAIN. TESLA HAD PREVIOUS ISSUED A TECHNICAL SERVICE BULLETIN (SB-19-12-001) TO REPLACE THESE DEFECTIVE MID AERO SHIELDS BUT IT APPEARS THE NEW PIECE IS AS SUSCEPTIBLE TO RAIN WATER DAMAGE AS THE ORIGIN PIECE. TESLA IS CHARGING ITS CUSTOMERS TO REPLACE DEFECTIVE MID AERO SHIELDS WHEN THESE DEFECTIVE PRODUCTS SHOULD BE COVERED UNDER WARRANTY OR SHOULD BE RECALLED. THE ORIGINAL MID AERO SHIELD PART NUMBER WAS 1104313-00-A. AFTER THE TSB, THE REPLACEMENT PART NUMBER IS 1104313-00-B. 1104313-00-B IS AS EQUALLY SUSCEPTIBLE TO WATER AND RAIN DAMAGE AS THE ORIGINAL PART. THERE ARE OVER 2000K COMPLAINTS ON THE FOLLOWING FORUMS; FORUMS DETAILING AERO SHIELD DAMAGE IS RAIN. HTTPS://TESLAMOTORSCLUB.COM/TMC/THREADS/RIPPED-UNDERCARRIAGE-COMPOSITE-FROM-THE-RAIN.131903/PAGE-11 HTTPS://FORUMS.TESLA.COM/FORUM/FORUMS/UNDERCARRIAGE-COMPOSITE-TRAY-RIPPED HTTPS://WWW.REDDIT.COM/R/TESLAMOTORS/COMMENTS/BAVO7P/MODEL_3_HARD_PLASTIC_VERSION_OF_UNDERCARRIAGE/ HTTPS://TESLAOWNERSONLINE.COM/THREADS/FRONT-UNDERBODY-AERO-PIECE-CAME-OFF-ON-HIGHWAY.11820/ HTTPS://WWW.QUORA.COM/WILL-DRIVING-FAST-THROUGH-1-OR-2-INCHES-OF-WATER-DAMAGE-THE-UNDERCARRIAGE

NHTSA ID

11245784

Incident

Aug 9, 2019

Mileage

4,110 mi

THIS IS FOR THE 2019 TESLA MODEL 3. PART NUMBER 1131205-00-C >PP-GF20< LOCATED IN THE FRUNK (FRONT TRUNK AREA) NEAR THE AIR INLET / 12VOLT BATTERY. I REMOVE THE SHROUD PART ABOVE THE ARE INLET AND BATTERY AND NOTICED THERE WAS PLAY (UP/DOWN) MOTION BY A PANEL FASTENER. UPON CLOSER OBSERVATION , I FOUND THE NOTED PART LISTED ABOVE PARTIAL BROKEN OFF HOLDING ON TO ONE OF THE VERY THIN ATTACHMENT POINTS. I BELIEVE THIS PART IS TO HOLE THE SHROUD MATING/FASTENING PART UP BY RESTING ON THE LOWER PART ASSEMBLY. AS YOU SEE IN THE IMAGES THIS IS A POOR DESIGN, WHICH SHOWS THREE VERY THIN SLIVERS OF MATERIAL JOINING TWO PARTS TOGETHER. PART #14 IN PARTS ASSEMBLY

NHTSA ID

11221856

Incident

Jun 21, 2019

Mileage

3,700 mi