Cracks in Tesla Model Y's Front End

author: FutureCar Staff    

In May, Nizar Kamel, a Tesla Model Y owner, came across news that some cars built 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 found that the cap was intact. However, he discovered a significant crack in a front aluminum casting, posing an even bigger problem.

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 road bump and pothole.

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

Tesla's Austin "Giga Texas" factory manufactures Model Y vehicles using a different approach compared to other Tesla models. Instead of multiple bonded and welded pieces, each suspension subframe is made from a single massive aluminum casting. The intention behind this design was to simplify manufacturing, reduce weight, and eliminate over 100 welds. However, a crack like the one Kamel discovered can compromise the overall structural integrity of the casting.

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

While there have been no other reported cases of cracked castings from customers, it does not mean that there are no other affected owners. Therefore, anyone who owns a Model Y built at the Giga factory in Austin should inspect their own vehicle by removing the plastic cover in the front trunk. If a crack is found, it is crucial to take the car to a Tesla service center as soon as possible.

Update 8/27/23 8:11 PM: A 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 revised to reflect this.

FutureCar Staff