Tesla has recalled more than 46,000 Cybertrucks in the US. This represents a significant portion of the futuristic vehicles that have been delivered to customers since production began.
Elon Musk’s car company has asked owners of the vehicles manufactured between November 2023 and late February 2025 to take them to a service centre for repairs amid fears a stainless steel trim panel could become detached while driving due to issues with the glue used in the manufacturing process. The distinctive stainless steel body panels are a signature design element of the Cybertruck, which has garnered substantial attention since its unveiling.
According to a filing with the National Highway Traffic Safety Administration (NHTSA), the panel can become detached while the vehicle is in motion and increase the risk of a crash. The NHTSA plays a crucial role in ensuring vehicle safety standards are maintained across the automotive industry.
“The cant rail, a stainless-steel exterior trim panel, can delaminate and detach from the vehicle. A detached panel can become a road hazard, increasing the risk of a crash,” Tesla’s filing to the agency stated. Automotive experts note that adhesive bonding with stainless steel presents unique challenges in vehicle manufacturing.
The company has fielded around 150 claims from drivers about the issue but Tesla told the NHTSA it was not aware of the problem causing any accidents so far. The company continues to monitor the situation closely as more vehicles are inspected.
New owners will be able to have the side-panel issue fixed for free as it will be covered under warranty. The remedy will use a structural adhesive which is not vulnerable to “environmental embrittlement”, according to the NHTSA. Environmental factors such as extreme temperatures, humidity, and exposure to elements can affect adhesive performance over time.
Notification letters will be sent to owners by May 19. This communication will provide detailed instructions for scheduling service appointments and explain the repair process to affected owners.
It’s the eighth time the Cybertruck has been slapped with a recall notice – previous recalls have been related to faults with acceleration pedals, windshield wipers and the car’s display screen. The vehicle has faced several production and design challenges since its initial announcement.
Industry observers note that the Cybertruck’s innovative design and unconventional manufacturing approach may contribute to these early production issues. Tesla’s use of stainless steel for exterior panels is unusual in modern automotive manufacturing.
The company’s service centers are preparing to address the issue efficiently to minimize inconvenience for Cybertruck owners. Tesla has developed a reputation for handling recalls through both in-person service and over-the-air software updates when applicable.
This particular issue, however, requires physical modification to the vehicle structure and cannot be resolved remotely. The repair involves applying a different type of adhesive that has been tested to withstand environmental conditions better than the original.
The Cybertruck, with its angular design and bulletproof exterior, has been one of Tesla’s most anticipated vehicles. The recall affects vehicles manufactured during the initial production phase, highlighting the challenges of bringing innovative designs to market.
Automotive safety experts emphasize that proactive recalls demonstrate a manufacturer’s commitment to addressing potential issues before they cause accidents or injuries. In this case, Tesla identified the problem through its quality control processes and customer feedback.
The stainless steel exterior panels of the Cybertruck are a departure from traditional automotive design, offering benefits such as corrosion resistance and durability, but also presenting unique manufacturing challenges. The adhesive connection between these panels is critical to both aesthetic appearance and structural integrity.
Tesla continues to refine its manufacturing processes at its Texas factory, where the Cybertruck is produced. The company has incorporated lessons learned from earlier models into its production systems, though the unique nature of the Cybertruck has required developing new manufacturing techniques.
Despite these early challenges, demand for the Cybertruck remains strong, with Tesla reporting substantial pre-orders. The vehicle represents Tesla’s entry into the lucrative pickup truck market, traditionally dominated by conventional automakers.
The company’s approach to addressing this recall will be closely watched by industry analysts and Tesla enthusiasts alike, as it demonstrates how the company handles manufacturing issues with its most distinctive vehicle to date.
