Tesla recalls over 46,000 Cybertrucks for panel detachment risk

Tesla has issued a recall for 46,096 units of the 2024-2025 Tesla Cybertruck due to a defect in the cant rail stainless steel panel, which may detach from the vehicle while in motion. The recall, designated by the National Highway Traffic Safety Administration (NHTSA) as campaign number 25V-170, was voluntarily initiated by Tesla following reports of panel delamination.

The issue involves a cosmetic component on the exterior of the vehicle known as the cant rail, which consists of an electrocoated steel stamping joined to a stainless steel panel using structural adhesive. Tesla determined that, in affected vehicles, the adhesive joint could weaken over time, potentially leading to the panel separating from the vehicle. If this occurs while the vehicle is in motion, the detached panel could pose a hazard to other road users, increasing the risk of a crash or injury.

Tesla first became aware of the issue on January 7, 2025, after identifying a customer complaint related to partial delamination of the cant rail panel. In response, the company launched an engineering study on January 13 to assess the extent of the issue. A second complaint was reported on January 31, prompting further investigation. A structural integrity test conducted on February 6 did not initially detect panel separation, but on February 21, the NHTSA Office of Defects Investigation notified Tesla of a vehicle owner questionnaire alleging a cant rail panel detachment. Over the following weeks, Tesla reviewed additional reports from social media and service records related to loose or separated cant rail panels. On March 11, after completing its investigation, Tesla made the decision to recall the affected vehicles. As of March 14, the company had recorded 151 warranty claims that may be linked to the defect, but no crashes, injuries, or fatalities associated with the issue have been reported.

To address the problem, Tesla will replace the cant rail assemblies on affected vehicles at no cost to owners. The new assemblies will feature an improved structural adhesive and additional reinforcement through a welded stud and clamping nut, which are designed to provide a more secure attachment. Tesla service centers were notified of the recall on March 20, while official owner notification letters are scheduled to be mailed by May 19. Vehicles still in production will begin receiving the updated components starting March 21.

Tesla owners with potentially affected vehicles will receive an official recall notice and are advised to contact a Tesla service center to arrange for the repair. Additional information can be found on the NHTSA recall database or by reaching out to Tesla customer support.