Cracks Found in Tesla Model Y's Front End

author: FutureCar Staff    

In May, Nizar Kamel, a Tesla Model Y owner, discovered that some cars produced 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, which raised further concerns.

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

Unable to find assistance from Tesla's service center, Kamel turned to social media to raise public awareness and attract Tesla's attention. He shared photos and videos showcasing the severity of the crack, revealing a noticeable gap that could accommodate the tip of a metal pick and allow light to pass through.

The Tesla factory in Austin, known as "Giga Texas," manufactures Model Y vehicles using a different process compared to other Tesla models. Instead of multiple bonded and welded pieces, each suspension subframe is created from a single massive aluminum casting. This approach aims to streamline manufacturing, reduce weight, and eliminate over 100 welds. However, the structural integrity of the entire subframe can be compromised if a crack like the one found by Kamel occurs.

Some skeptics questioned whether Kamel's car had been involved in an accident that may have caused the crack. However, Kamel clarified that his car was only five months old, had never been in any accidents, 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 have been no other reported cases of cracked castings from customers, it does not guarantee that there are no other affected vehicles. Therefore, owners of Model Y cars manufactured at the Giga factory in Austin are encouraged to check their vehicles by removing the plastic cover in the front trunk. If a crack is found, it is recommended to bring the car to a Tesla service center as soon as possible.

Update 8/27/23 8:11PM: The previous version of the story incorrectly stated that the Tesla service center did not see Kamel's car until July. It has been clarified that Kamel had prior obligations, which delayed him from bringing his car in for service until July.

FutureCar Staff