Scary Cracks in Tesla Model Y's Gigacast 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 promptly checked his brake fluid reservoir and thankfully found the cap intact. However, he discovered a significant crack in a front aluminum casting, which posed a more significant problem.

Kamel immediately contacted Tesla and requested the car be 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.

Frustrated with Tesla's lack of assistance, Kamel turned to social media to raise public awareness and capture Tesla's attention. He posted photos and videos showcasing the severity of the crack, which was not just a hairline fracture. The gap was large enough to fit the tip of a metal pick, and light could be seen shining through.

Tesla's Austin "Giga Texas" factory takes a different approach in manufacturing Model Y vehicles compared to other Tesla models. Instead of multiple pieces bonded and welded together, 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 downside is that a crack like the one Kamel discovered can compromise the structural integrity of the entire casting.

Skeptics questioned whether Kamel's car had been involved in a crash that may have caused the casting damage. Kamel firmly stated that his car was only five months old, had never been in an accident, and was exclusively driven on normal roads. Additionally, there have been rumors of issues with producing these large castings at the Giga factory.

While there are no other known cases of cracked castings from customers, it does not rule out the possibility of 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 8:11 PM: The previous version of the story inaccurately stated that the Tesla service center refused to see Kamel's car until July. However, it has been clarified that Kamel had prior obligations that delayed him from bringing his car in for service until July.

FutureCar Staff