Cracks in Tesla Model Y Front End

author: FutureCar Staff    

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

Kamel immediately contacted Tesla and requested a service check for his car. Unfortunately, due to personal obligations, he was unable to bring the vehicle in until July. When Tesla finally inspected the car, they assured him 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 road bump and pothole.

Unable to find assistance from Tesla's service center, Kamel turned to social media to raise public awareness and catch Tesla's attention. He shared photos and videos highlighting the severity of the crack, which is not just a hairline fracture. The gap is large enough to fit the tip of a metal pick, and light can be seen shining through it.

Tesla's Austin "Giga Texas" factory employs a different manufacturing process for the Model Y compared to other Tesla models. Instead of multiple bonded and welded pieces, each suspension subframe is made from a single massive aluminum casting. This approach aims to reduce weight and simplify manufacturing by eliminating over 100 welds. However, a crack like the one Kamel discovered can compromise the structural integrity of the entire casting.

Some skeptics questioned whether the car had been involved in a crash that may have damaged the casting. Kamel clarified that his five-month-old car had never been in an accident and had only been driven on normal roads. Additionally, there have been rumors of issues with the production of these large castings at the Giga factory.

While there are no other reported cases of cracked castings from customers, it does not 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 frunk. If a crack is found, it is crucial to take the car to a 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 refused to see Kamel's car until July. However, Kamel had prior obligations that delayed him from bringing his car in for service until July. The story has been updated to reflect this clarification.

FutureCar Staff