Tesla Model Y Owner Discovers Frightening Fractures in Gigacast Front

author: FutureCar Staff    

Tesla Model Y owner Nizar Kamel recently discovered a potential issue with cars built at Tesla's new factory in Austin, Texas. Reports indicated that some of these vehicles may have missing brake fluid caps, which could pose a significant problem. Concerned, Kamel checked his own brake fluid reservoir and fortunately found the cap intact. However, he made another troubling discovery—a sizable crack in a front aluminum casting.

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

Unable to find assistance from Tesla's service center, Kamel turned to social media to raise awareness and capture Tesla's attention. He shared photos and videos showcasing the severity of the crack. The visuals depicted a gap large enough to fit the tip of a metal pick, with visible light shining through.

The manufacturing process for Model Y vehicles at Tesla's Austin "Giga Texas" factory differs slightly from other Tesla models. Instead of using multiple bonded and welded pieces for each suspension subframe, the factory employs a single massive aluminum casting. This approach aims to streamline production by reducing over 100 welds and minimizing weight. However, a crack like the one Kamel discovered can compromise the structural integrity of the entire casting.

Some skeptics questioned whether the car had been involved in an accident that may have caused the casting damage. Kamel firmly denied this, 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 producing these large castings at the Giga factory.

While there have been no other reported instances of cracked castings from customers, it does not mean that there are no other affected vehicles. Owners of Model Y cars built at the Giga factory in Austin are advised to inspect their vehicles themselves 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 incorrectly stated that the Tesla service center would not 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 amended to reflect this.

FutureCar Staff