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 his own vehicle, Kamel immediately checked his brake fluid reservoir and fortunately found the cap intact. However, he discovered a significant crack in the front aluminum casting, which raised even greater concerns.

Kamel promptly contacted Tesla and requested that service technicians inspect his car. Unfortunately, due to personal obligations, he was unable to bring his vehicle in for inspection until July. When he finally had the opportunity to have Tesla examine the car, they reportedly assured him that it was safe to drive and did not address the crack. Since then, Kamel has been driving with apprehension, hoping that the crack does not worsen with every bump and pothole.

Unable to find assistance from Tesla's service center, Kamel turned to social media as a means to raise awareness and grab Tesla's attention. He shared photos and videos showcasing 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 factory, also known as "Giga Texas," employs a different manufacturing approach for Model Y's compared to other Tesla models. Instead of multiple bonded and welded pieces, each suspension subframe is made from a single massive aluminum casting. This design choice aimed to reduce weight, simplify manufacturing, and eliminate over 100 welds. However, the integrity of the entire structure can be compromised by a crack like the one Kamel discovered.

Some skeptics questioned whether the car had been involved in a crash that may have caused the casting damage. Kamel clarified that his five-month-old vehicle had never been in an accident and had only been driven on regular roads. Additionally, rumors have circulated about issues with manufacturing 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 other owners are not affected. Owners of Model Y's 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 as soon as possible.

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

FutureCar Staff