Cracks in Tesla Model Y's Gigacast Front End Raise Concerns

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, might have missing brake fluid caps. Concerned about the safety of his own vehicle, Kamel promptly checked his brake fluid reservoir and fortunately found the cap intact. However, he discovered a significant issue—a sizable crack in a front aluminum casting.

According to Kamel, he immediately contacted Tesla to have his car examined by service technicians. Unfortunately, due to personal obligations, he was unable to bring the car in for inspection until July. When Tesla finally inspected the vehicle, they allegedly 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 road bump and pothole.

Since Tesla's service center did not provide assistance, 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, revealing a gap large enough to fit the tip of a metal pick and allowing light to shine through.

The Tesla factory in Austin, also known as "Giga Texas," 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. This design aims to simplify manufacturing, reduce weight, and eliminate over 100 welds. However, a crack like the one Kamel discovered poses a risk to 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, however, clarified that his car was only five months old, had never been in an accident, and had only been driven on regular roads. Additionally, there have been rumors about issues with producing these massive castings at the Giga factory.

While there are no other reported instances of cracked castings from customers, it does not mean that other affected customers do not exist. Owners of Model Y vehicles built at the Giga factory in Austin are advised to inspect their cars by removing the plastic cover in the front trunk. If a crack is found, it is crucial to take the vehicle to a service center as soon as possible.

Update 8/27/23 8:11PM: A previous version of the story inaccurately 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 correction.

FutureCar Staff