Tesla Cybertruck Recall Issued Over Risk Trim Panels Could Detach While Driving: NHTSA

Recall affects all model year 2024 through 2025 Cybertruck vehicles manufactured between November 13, 2023 and February 7, 2025.

Federal highway safety officials have announced a Tesla recall impacting 46,096 Cybertruck vehicles, due to the risk that an exterior trim panel may detach from the vehicles while in motion, increasing the risk of an auto accident.

The U.S. National Highway Safety Administration (NHTSA) issued the Tesla Cybertruck recall on March 19, which impacts all 2024 through 2025 model year Tesla Cybertruck vehicles, following reports of the cant rail detaching.

The cant rail is a stainless-steel exterior trim panel that was placed on the electric pick-up trucks for cosmetic purposes only. However, the rail’s adhesive could become brittle in certain environments, which may lead to the panel to detaching from the vehicle, and creating a roadway hazard.

While Tesla has not received any reports of accidents or injuries related to the issue, the automaker has received at least 151 warranty claims.

According to the NHTSA’s safety recall report (PDF), Tesla first became aware of the issue on January 7, 2025, after receiving a field complaint regarding a cant rail partially detaching.  

After initiating an engineering study to investigate the issue, the manufacturer received another case of a cant rail’s partial detachment on January 31.

The engineering study, consisting of an inspection and pull test, did not detect any episodes of separation. However, the NHTSA Office of Defects Investigation (ODI) notified Tesla of a vehicle owner questionnaire (VOQ) alleging that a cant rail detached on February 21 as well.

From February 21 through March 7, the manufacturer investigated the VOQ, complaints identified on social media, and service records of loose or separated cant rails. On March 11, Tesla initiated a voluntary recall (PDF) affecting all 2024 through 2025 Cybertruck vehicles manufactured between November 13, 2023 and February 7, 2025.

As part of the recall, Tesla will replace the cant rail assembly with a new version that meets durability testing requirements, using a different adhesive to ensure bonding in all environments. The new rail will also be reinforced with a stud welded to the panel and secured by a nut that clamps the panel to the vehicle structure. Customers will start receiving notification letters on May 19, 2025, with details on how to schedule this free replacement.

Tesla’s number for this recall is SB-25-10-001. Customers may contact Tesla customer service at 1-877-798-3752, or the company’s contact for this recall, Sarah Shiver, via email at sarah.shiver@dot.gov.

Owners with any additional questions may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-888-275-9171), or go to www.nhtsa.gov.

Additional Tesla Recalls and Lawsuits

Over the past year, Tesla has faced numerous issues with its vehicles. Last month, more than 375,000 Tesla vehicles were recalled after a software malfunction was discovered that caused a power steering assist failure, which could increase the risk of accidents, injuries or death.

The NHTSA also initiated a Tesla “Smart Summon” feature investigation in January of this year, after reports of at least 16 accidents caused by defects in the vehicles’ full-self-driving systems, which are designed to control the cars with the help of a mobile app.

That same month, Tesla also issued a recall of nearly 240,000 vehicles due to a rearview camera failure, which could lead to a crash. 

An earlier Tesla self-driving investigation was launched by federal regulators in October 2024, after four pedestrian accidents occurred while vehicles were in autonomous driving modes, one involving a fatality.

Also in 2024, a wrongful death lawsuit was also filed against Tesla, claiming that deficiencies in Tesla’s autopilot system led to the death of a 33-year-old man after his vehicle collided with a fire truck, despite the company portraying its autopilot feature as a safe and fully autonomous driving system.