Tesla Model Y Cracks in 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 his own vehicle, Kamel checked the brake fluid reservoir and found that the cap was intact. However, he discovered a significant crack in a front aluminum casting.

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. Since then, Kamel has been driving with anxiety, hoping that the crack does not worsen with every bump and pothole.

Unable to receive assistance from Tesla's service center, Kamel turned to social media to raise awareness and catch 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 employs a different manufacturing process for Model Y vehicles. Instead of using multiple bonded and welded pieces for each suspension subframe, a single massive aluminum casting is used. This approach aims to reduce weight, simplify production, and eliminate over 100 welds. However, the reliance on one-piece castings makes the structural integrity vulnerable to cracks like the one found in Kamel's car.

Some skeptics questioned whether the car had been involved in an accident that may have caused the casting damage. Kamel refuted these claims, stating 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 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 individuals. 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 frunk. 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 incorrectly stated that the Tesla service center refused to see Kamel's car until July. However, Kamel's prior obligations prevented him from bringing his car in for service until July. The story has been revised to reflect this.

FutureCar Staff