Cracks Discovered in Tesla Model Y Front End

author: FutureCar Staff    

In May, Nizar Kamel, a Tesla Model Y owner, became aware of a potential issue with cars produced at Tesla's new factory in Austin, Texas. It was reported that some vehicles may have missing brake fluid caps, which could pose a safety risk. Concerned, Kamel checked his own brake fluid reservoir and fortunately found the cap intact. However, he discovered a significant crack in a front aluminum casting, indicating a more serious problem.

Kamel promptly contacted Tesla to have his car inspected by service technicians. However, due to personal obligations, he was unable to bring the vehicle in for assessment until July. When Tesla finally examined the car, they allegedly assured Kamel that it was safe to drive and did not address the issue. As a result, Kamel has been driving with anxiety, hoping that the crack does not worsen with each road bump and pothole.

Since Tesla's service center did not provide assistance, Kamel turned to social media as a means to raise public awareness and grab Tesla's attention. He shared photos and videos showcasing the severity of the crack, which revealed a visible gap and allowed light to pass through.

The Austin "Giga Texas" factory, where Tesla manufactures Model Y vehicles, employs a different approach compared to other Tesla models. Instead of using multiple bonded and welded pieces for each suspension subframe, they utilize a single massive aluminum casting. This design choice aimed to streamline production, reduce weight, and eliminate over 100 welds. However, the use of a single casting makes the structural integrity vulnerable to cracks like the one observed by Kamel.

When skeptics questioned Kamel about the possibility of the car being involved in a previous accident that could have caused the damage, he firmly denied any such incidents. He emphasized that his car was only five months old and had exclusively been driven on regular roads. Additionally, rumors have circulated about issues with the production of these large castings at the Giga factory.

While no other instances of cracked castings have been reported by customers, it does not necessarily mean that there are no other affected vehicles. Owners of Model Y cars built at the Giga factory in Austin are advised to inspect their vehicles by removing the plastic cover in the front trunk. If a crack is found, it is crucial to take the car to a service center promptly.

Update 8/27/23 8:11PM: The previous version of the story stated that the Tesla service center could not see Kamel's car until July. However, it has been clarified that Kamel's prior obligations prevented him from bringing his car in for service until July. The story has been updated accordingly.

FutureCar Staff