Tesla's latest recall? wheels may fall off cybertrucks

At a glance:

• Tesla recalls 173 RWD Cybertruck Long Range models over brake rotor stud holes that may crack
• The 11th Cybertruck recall involves faulty grease on lug nuts that could cause wheels to detach
• Tesla will replace wheel hubs, rotors, and lug nuts free of charge for affected vehicles

The Recall Details

Tesla has issued its 11th recall for the Cybertruck, this time affecting Rear Wheel Drive (RWD) Cybertruck Long Range models due to potentially dangerous brake rotor issues. According to a notice posted by the National Highway Traffic Safety Administration (NHTSA), the problem centers on "brake rotor stud holes may crack and allow the stud to separate from the wheel hub." This defect could lead to wheels detaching while driving, creating a serious safety hazard.

Tesla's description of the defect is particularly concerning: "On affected vehicles, higher severity road perturbations and cornering may strain the stud hole in the wheel rotor, causing cracks to form. If cracking propagates with continued use and strain, the wheel stud could eventually separate from the wheel hub." This means that some RWD Cybertruck owners could find themselves overtaken by their own wheels while driving.

The Root Cause

The issue stems from the use of incorrect grease on lug nuts that secure the 18-inch wheels to the brake rotor. Sean Tucker, managing editor at Kelley Blue Book, explains that "this is literally about some grease [Tesla] discovered on the lug nuts that tighten to hold the 18-inch wheel to the brake rotor." The inadequate grease wasn't reducing friction sufficiently, which could cause the nuts to loosen over time, leading to vibrations that might crack the brake rotor.

Tucker clarified that Tesla has since changed the grease, but "that message didn't get to the production floor in time, and they built 173 with the wrong grease." He describes this as "a very specific materials problem" rather than a widespread design flaw. The recall applies specifically to trucks built on certain dates using a particular shipment of lug nuts and grease, affecting only vehicles with 18-inch wheels produced during that timeframe.

Affected Vehicles and Remedies

The recall impacts exactly 173 Cybertruck models, a number that might suggest extremely low production volumes. However, Tucker emphasizes this isn't the case, explaining that "it's a subset of a subset" of Cybertrucks. The issue is limited to vehicles manufactured during a specific period when the incorrect grease was used in production.

Fortunately, Tesla has committed to addressing the problem comprehensively and at no cost to owners. The company will completely replace the wheel hubs, rotors, and lug nuts for all affected vehicles. This proactive approach aims to prevent any potential accidents resulting from wheel detachment while maintaining customer trust in the electric pickup truck.

Context of Previous Issues

This latest recall comes on the heels of another embarrassing issue for Tesla's electric pickup. Last year, nearly all Cybertrucks had to be recalled because Tesla used the wrong glue on a steel trim panel that could become detached while driving. That recall affected a much larger proportion of vehicles compared to this current issue, highlighting ongoing quality control challenges for the unconventional vehicle.

The Cybertruck has faced numerous recalls since its introduction, with this being the 11th such action. These quality issues have emerged despite Tesla's ambitious production targets and the vehicle's polarizing design that has generated significant attention since its unveiling.

Sales Performance

Despite the enthusiastic reception to its futuristic design, the Cybertruck has struggled to meet Tesla's sales expectations. Elon Musk had famously claimed "Demand is off the charts!" at the end of 2023, citing more than a million reservations for the polygonal pickup. However, the actual sales figures tell a different story. The previous recall involving incorrect glue revealed that Tesla had shifted only 46,096 Cybertrucks in the first 14 months of sales, a number significantly below what the company had likely projected.

Tucker acknowledges that "the Cybertruck is not selling in the numbers that Tesla expected it to," though he notes that the current recall is "really just a matter of a small production change that wasn't communicated to the factory floor in time." The combination of quality issues and modest sales performance presents challenges for Tesla as it seeks to establish the Cybertruck as a significant contributor to its business.