In a move that underscores the growing pains of even the most innovative automakers, Tesla has issued a recall for approximately 6,200 of its futuristic Cybertrucks. The reason? A surprisingly simple assembly line mix-up involving the wrong adhesive, which could cause the vehicle's distinctive off-road LED light bars to detach while driving.
This marks the second significant recall for Tesla in a short period, following a recent callback of about 13,000 Model 3 and Model Y vehicles for a separate powertrain issue. For the Cybertruck, the problem isn't with its rugged stainless-steel exoskeleton or its high-voltage electrical system, but with the glue meant to hold a key accessory in place.
The Root of the Problem: A Primer vs. Adhesive Mix-Up
According to an official recall notice published by the U.S. National Highway Traffic Safety Administration (NHTSA), the issue stems from a specific error at Tesla’s Texas Gigafactory. The recall affects Cybertrucks manufactured between November 13, 2023, and November 5, 2024.
The NHTSA report pinpoints the cause: during assembly, workers sometimes accidentally used a product called BetaSeal adhesive instead of the proper BetaPrime primer. While both sound similar, they serve different purposes. Using the wrong one compromises the bond strength. As a result, normal road vibrations and shocks—especially during off-road adventures—could cause the LED light bar to come loose and separate from the vehicle.
"A loose or detached light bar can create a road hazard, potentially increasing the risk of a crash or injury to other road users," the NHTSA stated. Thankfully, the agency confirms that Tesla has not received any reports of accidents, injuries, or fatalities related to this issue. The company has, however, acknowledged 619 warranty claims and one field report concerning the problem.
For full technical details, you can review the official NHTSA recall report here.
A Complicated Installation Process
Adding a layer of complexity to the recall is how customers acquired the light bars. The accessory was available as a factory-installed option, added later through a Tesla Service Center, or even as a DIY kit for owners to install themselves.
This multi-channel approach arose because, in some jurisdictions, Tesla staff are not legally permitted to install certain aftermarket electronic components. It remains unclear if owner-installed units are more or less susceptible to the adhesive problem, but Tesla's recall covers all affected vehicles, regardless of how the light bar was fitted.
Tesla’s Response: Inspection, Replacement, and a New Fuse
In response to the discovery, Tesla has committed to a comprehensive and customer-friendly resolution. The company will notify all affected Cybertruck owners and instruct them to schedule an inspection at a Tesla Service Center.
The remedy involves:
- Inspection: Technicians will thoroughly check the off-road light bar for any signs of looseness or damage.
- Free Replacement: If any issue is found, the entire light bar assembly will be replaced at no cost to the owner, using the correct primer and adhesive.
- Enhanced Safety: Perhaps most notably, Tesla will add a mechanical fuse to the new or re-secured light bar assembly. This secondary safety measure is designed to ensure that even in a highly unlikely future failure, the component would not become a dangerous projectile.
This transparent and proactive approach is crucial for Tesla, which is keen to maintain customer trust and its brand image as a leader in automotive technology. You can learn more about the Cybertruck and its features on Tesla's official website here.
A Broader Pattern of Challenges for Tesla
This Cybertruck recall is not an isolated incident. It represents Tesla's tenth official recall in less than two years. Previous issues have ranged from seemingly minor problems, like loose trunk trim pieces, to more serious concerns, such as misaligned pedals.
The Cybertruck itself has faced a rocky start. Sales have reportedly fallen short of internal expectations. A significant hurdle is the vehicle's inability to be certified as road-legal in key markets like the European Union, where its sharp angular design and rigid stainless-steel body are deemed non-compliant with pedestrian safety regulations.
In a curious twist to boost the model's visibility and numbers, reports emerged earlier this year that Elon Musk had his other companies, SpaceX and xAI, purchase an entire fleet of Cybertrucks. While this move likely provided a temporary sales bump, it does little to address the fundamental quality control and regulatory challenges the vehicle faces.
As Tesla navigates this latest "sticky" situation, the automotive world will be watching closely to see how quickly and effectively the company can resolve the issue for its most ardent early adopters and prove that its manufacturing quality can match its ambitious vision.