Cracks Discovered in Tesla Model Y Gigacast Front End

author: FutureCar Staff    

In May, Nizar Kamel, a Tesla Model Y owner, discovered that some cars built at Tesla's new factory in Austin, Texas, could potentially have missing brake fluid caps. Concerned about the safety of his own vehicle, Kamel checked his brake fluid reservoir and found that the cap was intact. However, he also discovered a significant crack in a front aluminum casting.

Kamel promptly contacted Tesla to have his car inspected by service technicians, but due to personal obligations, he was unable to bring the car in until July. When Tesla finally examined the vehicle, they reportedly assured Kamel that it was safe to drive and did not address the crack. Since then, Kamel has been driving with anxiety, hoping that the crack does not worsen with every bump and pothole.

Since Tesla's service center failed to assist him, Kamel turned to social media to raise public awareness and catch Tesla's attention. He shared photos and videos showcasing the severity of the crack, which is not just a hairline fracture but rather a gap large enough for a metal pick to fit through, with light visible.

The Tesla factory in Austin, known as "Giga Texas," produces Model Y vehicles using a different manufacturing process compared to other Tesla models. Instead of multiple bonded and welded pieces, each suspension subframe is made from a single massive aluminum casting. This method aims to reduce weight and simplify manufacturing by eliminating over 100 welds. However, a crack in such a casting can compromise the structural integrity of the entire component.

Responding to skeptics who questioned whether the car had been involved in an accident, Kamel clarified that his five-month-old vehicle had never been in a crash and had only been driven on regular roads. Additionally, there have been rumors of issues with producing these large castings at the Giga factory.

While there are no other reported cases of cracked castings from customers, it is essential for Model Y owners whose vehicles were manufactured at the Giga factory in Austin to inspect their cars. By removing the plastic cover in the frunk, they can check for any cracks. If a crack is found, it is advisable to take the car to a service center as soon as possible.

Update 8/27/23 8:11 PM: In a previous version of the story, it was incorrectly stated that the Tesla service center refused to see Kamel's car until July. However, Kamel had personal obligations that prevented him from bringing his car in for service until July. The story has been updated to reflect this clarification.

FutureCar Staff