2025 Tesla Cybertruck problems

SUSPENSION

I am submitting this complaint regarding two serious safety-related failures with my Tesla Cybertruck: a braking-system malfunction and a rear suspension/subframe failure at approximately 12,500 miles. The vehicle previously experienced a significant braking problem that required repair by an authorized Tesla Service Center. The initial repair did not properly resolve the issue, requiring the vehicle to return for additional service. Because the problem involved the braking system, I was concerned about the vehicle's ability to stop safely and predictably, creating a risk of a serious collision. Tesla's service records should document the diagnosis, repairs, and any related fault codes. At approximately 12,500 miles, the vehicle experienced a major failure involving the rear suspension/subframe. The rear suspension separated/dropped in relation to the subframe, causing significant damage. Tesla inspected the vehicle and performed extensive repairs involving the rear subframe, including component/part number 1250562-00-E. This failure created a serious safety risk because the rear suspension/subframe affects vehicle stability, wheel positioning, handling, and control. If this failure had occurred while traveling at highway speed, it could have caused loss of control, a serious collision, injury, or death. Due to the condition of the vehicle, I had it towed rather than driving it. To my knowledge, there was no meaningful advance warning that a major suspension/subframe failure was about to occur. Tesla should have diagnostic logs, photographs, technician findings, repair records, and information concerning the failed components. I also have photographs and service documentation. Having experienced both a braking-system problem and a major suspension/subframe failure at low mileage has caused serious concerns regarding the safety of this vehicle. I am requesting that NHTSA investigate whether similar failures have occurred in other Cybertrucks.

NHTSA complaint #11758503 — an unverified report by a vehicle owner.

SERVICE BRAKES

I am submitting this complaint regarding two serious safety-related failures with my Tesla Cybertruck: a braking-system malfunction and a rear suspension/subframe failure at approximately 12,500 miles. The vehicle previously experienced a significant braking problem that required repair by an authorized Tesla Service Center. The initial repair did not properly resolve the issue, requiring the vehicle to return for additional service. Because the problem involved the braking system, I was concerned about the vehicle's ability to stop safely and predictably, creating a risk of a serious collision. Tesla's service records should document the diagnosis, repairs, and any related fault codes. At approximately 12,500 miles, the vehicle experienced a major failure involving the rear suspension/subframe. The rear suspension separated/dropped in relation to the subframe, causing significant damage. Tesla inspected the vehicle and performed extensive repairs involving the rear subframe, including component/part number 1250562-00-E. This failure created a serious safety risk because the rear suspension/subframe affects vehicle stability, wheel positioning, handling, and control. If this failure had occurred while traveling at highway speed, it could have caused loss of control, a serious collision, injury, or death. Due to the condition of the vehicle, I had it towed rather than driving it. To my knowledge, there was no meaningful advance warning that a major suspension/subframe failure was about to occur. Tesla should have diagnostic logs, photographs, technician findings, repair records, and information concerning the failed components. I also have photographs and service documentation. Having experienced both a braking-system problem and a major suspension/subframe failure at low mileage has caused serious concerns regarding the safety of this vehicle. I am requesting that NHTSA investigate whether similar failures have occurred in other Cybertrucks.

NHTSA complaint #11758503 — an unverified report by a vehicle owner.

WHEELS

My 2025 Tesla AWD Cybertruck's rear driver 20" wheel came loose, creating a loud banging noise. The wheel nuts on 2 of the studs worked finger-loose, and one of the studs broke off the hub. The truck had 9000 miles on the odometer. Tesla's service dept blamed me for improperly rotating the tires, but I had never removed or replaced them.

NHTSA complaint #11750853 — an unverified report by a vehicle owner.

LANE DEPARTURE: BLIND SPOT DETECTION

Interior factory component off-gassing causes a recurring residue film on the internal glass of the forward-facing camera, completely blinding the vehicle's primary safety systems and FSD. Tesla Service refuses to rectify the defect under warranty, calling it standard maintenance, forcing owners to drive with compromised driver-assist features or pay recurring out-of-pocket fees.

NHTSA complaint #11750193 — an unverified report by a vehicle owner.

FORWARD COLLISION AVOIDANCE: WARNINGS

Interior factory component off-gassing causes a recurring residue film on the internal glass of the forward-facing camera, completely blinding the vehicle's primary safety systems and FSD. Tesla Service refuses to rectify the defect under warranty, calling it standard maintenance, forcing owners to drive with compromised driver-assist features or pay recurring out-of-pocket fees.

NHTSA complaint #11750193 — an unverified report by a vehicle owner.

FORWARD COLLISION AVOIDANCE: ADAPTIVE CRUISE CONTROL

Interior factory component off-gassing causes a recurring residue film on the internal glass of the forward-facing camera, completely blinding the vehicle's primary safety systems and FSD. Tesla Service refuses to rectify the defect under warranty, calling it standard maintenance, forcing owners to drive with compromised driver-assist features or pay recurring out-of-pocket fees.

NHTSA complaint #11750193 — an unverified report by a vehicle owner.

STRUCTURE:BODY

The vehicle's rear structural Giga Casting sustained severe structural failure, exhibiting two distinct cracks following an impact. The vehicle and the damaged casting are fully available for inspection upon request at my current location/service center. The safety risk is extreme. The Giga Casting is a core load-bearing structural component of the vehicle. Cracking in this area severely compromises the vehicle's structural integrity. If the vehicle continues to be driven, any subsequent minor impact or even routine road vibrations could lead to a catastrophic structural collapse, complete loss of vehicle control, or unpredictable battery pack intrusion, putting my life and other road users at severe risk. the structural cracks on the Giga Casting have been inspected and confirmed by the Tesla Service Center and I been told by the technician the casting is very easy to get damaged. When the accident happened the most cybertruck get damaged in the casting

NHTSA complaint #11746900 — an unverified report by a vehicle owner.

VEHICLE SPEED CONTROL

The contact owns a 2025 Tesla Cybertruck. The contact stated that while pulling into a charging station with the self-driving system activated, the vehicle stopped in front of the payment pole; however, the vehicle inadvertently accelerated through the barrier gate arm, and the arm was fractured. The barrier scratched the passenger’s side bumper. A police report was not filed. There were no injuries sustained. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was approximately 13,000.

NHTSA complaint #11745888 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM:ADAS:AUTONOMOUS/SELF DRIVING

The contact owns a 2025 Tesla Cybertruck. The contact stated that while pulling into a charging station with the self-driving system activated, the vehicle stopped in front of the payment pole; however, the vehicle inadvertently accelerated through the barrier gate arm, and the arm was fractured. The barrier scratched the passenger’s side bumper. A police report was not filed. There were no injuries sustained. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was approximately 13,000.

NHTSA complaint #11745888 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

PCS2 failure. The PCS2 board manages charging and power conversion. Failures typically start by restricting home AC charging speeds (e.g., dropping from 48A down to 24A) and can eventually result in a complete loss of AC charging and a "Charging Unavailable" alert.

NHTSA complaint #11745238 — an unverified report by a vehicle owner.

SEATS

My 2025 Tesla Cybertruck AWD (VIN: [XXX] ) has a recurring failure of the right rear seat occupant detection system, which governs airbag deployment and is certified by Tesla to meet FMVSS 208. The same alert (internal code RCM2_a698) persisted through two official repairs at Tesla Palo Alto: 1st repair (Invoice XXX, 8/22/2025): seat belt buckle replaced. Alert recurred 2 days later, August 24, 2025. 2nd repair (Invoice XXX, 9/18/2025): harness assembly replaced. Tesla then performed a Visual Quality Check, recording in the invoice: "Technician performed a visual quality check to ensure its condition meets our standards." Vehicle returned as repaired. Relying on Tesla's written certification, I reinstalled my [XXX] son's car seat in that position. He rode there daily for approximately 7 months (September 2025 - April 2026). On April 21, 2026, I tested the seat and found the sensor still actively failing - unable to detect an adult occupant. My spouse witnessed this. I have 30-second video. Alert RCM2_a698 remains active in Tesla's systems today, confirmed by screenshot. This is my family's only vehicle. My wife currently uses the right rear seat. Airbag deployment for that seat cannot be relied upon. Tesla has been notified and has not resolved this issue. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11737205 — an unverified report by a vehicle owner.

SEAT BELTS

My 2025 Tesla Cybertruck AWD (VIN: [XXX] ) has a recurring failure of the right rear seat occupant detection system, which governs airbag deployment and is certified by Tesla to meet FMVSS 208. The same alert (internal code RCM2_a698) persisted through two official repairs at Tesla Palo Alto: 1st repair (Invoice XXX, 8/22/2025): seat belt buckle replaced. Alert recurred 2 days later, August 24, 2025. 2nd repair (Invoice XXX, 9/18/2025): harness assembly replaced. Tesla then performed a Visual Quality Check, recording in the invoice: "Technician performed a visual quality check to ensure its condition meets our standards." Vehicle returned as repaired. Relying on Tesla's written certification, I reinstalled my [XXX] son's car seat in that position. He rode there daily for approximately 7 months (September 2025 - April 2026). On April 21, 2026, I tested the seat and found the sensor still actively failing - unable to detect an adult occupant. My spouse witnessed this. I have 30-second video. Alert RCM2_a698 remains active in Tesla's systems today, confirmed by screenshot. This is my family's only vehicle. My wife currently uses the right rear seat. Airbag deployment for that seat cannot be relied upon. Tesla has been notified and has not resolved this issue. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11737205 — an unverified report by a vehicle owner.

AIR BAGS

My 2025 Tesla Cybertruck AWD (VIN: [XXX] ) has a recurring failure of the right rear seat occupant detection system, which governs airbag deployment and is certified by Tesla to meet FMVSS 208. The same alert (internal code RCM2_a698) persisted through two official repairs at Tesla Palo Alto: 1st repair (Invoice XXX, 8/22/2025): seat belt buckle replaced. Alert recurred 2 days later, August 24, 2025. 2nd repair (Invoice XXX, 9/18/2025): harness assembly replaced. Tesla then performed a Visual Quality Check, recording in the invoice: "Technician performed a visual quality check to ensure its condition meets our standards." Vehicle returned as repaired. Relying on Tesla's written certification, I reinstalled my [XXX] son's car seat in that position. He rode there daily for approximately 7 months (September 2025 - April 2026). On April 21, 2026, I tested the seat and found the sensor still actively failing - unable to detect an adult occupant. My spouse witnessed this. I have 30-second video. Alert RCM2_a698 remains active in Tesla's systems today, confirmed by screenshot. This is my family's only vehicle. My wife currently uses the right rear seat. Airbag deployment for that seat cannot be relied upon. Tesla has been notified and has not resolved this issue. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11737205 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

My 2025 Tesla Cybertruck AWD (VIN: [XXX] ) was returned to me after the first service visit (Invoice XXX Tesla Palo Alto, 8/22/2025) with the Pedestrian Warning System (PWS) speaker disconnected. The disconnection occurred during front-end service work at that visit, which included front fascia inspection and removal. The technician did not reconnect the PWS speaker before returning the vehicle. The disconnection was not discovered until the second service visit (Invoice XXX, Tesla Palo Alto, 9/18/2025), at which point Tesla's own invoice documented: "The issue was caused by a disconnected front pedestrian warning speaker. Technician reconnected the front pedestrian warning speaker to resolve the issue." The [XXX] s therefore operated with a disconnected PWS for approximately 4 weeks — from August 22 to September 18, 2025 — without my knowledge. During this entire period, the vehicle was not emitting the required audible low-speed alert. The PWS emits an audible alert at low speeds to warn pedestrians, cyclists, and visually impaired individuals of the vehicle's approach. This system is required under FMVSS 141 (Minimum Sound Requirements for Hybrid and Electric Vehicles). This is a service-inflicted deactivation of a federally-required pedestrian safety system. The deactivation was caused by Tesla's Palo Alto service center (4180 El Camino Real, Palo Alto, CA 94306) during routine warranty repair work. The vehicle was returned to me without disclosure of the disconnection. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11737207 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

My 2025 Tesla Cybertruck AWD (VIN: [XXX] ) was returned to me after the first service visit (Invoice XXX Tesla Palo Alto, 8/22/2025) with the Pedestrian Warning System (PWS) speaker disconnected. The disconnection occurred during front-end service work at that visit, which included front fascia inspection and removal. The technician did not reconnect the PWS speaker before returning the vehicle. The disconnection was not discovered until the second service visit (Invoice XXX, Tesla Palo Alto, 9/18/2025), at which point Tesla's own invoice documented: "The issue was caused by a disconnected front pedestrian warning speaker. Technician reconnected the front pedestrian warning speaker to resolve the issue." The [XXX] s therefore operated with a disconnected PWS for approximately 4 weeks — from August 22 to September 18, 2025 — without my knowledge. During this entire period, the vehicle was not emitting the required audible low-speed alert. The PWS emits an audible alert at low speeds to warn pedestrians, cyclists, and visually impaired individuals of the vehicle's approach. This system is required under FMVSS 141 (Minimum Sound Requirements for Hybrid and Electric Vehicles). This is a service-inflicted deactivation of a federally-required pedestrian safety system. The deactivation was caused by Tesla's Palo Alto service center (4180 El Camino Real, Palo Alto, CA 94306) during routine warranty repair work. The vehicle was returned to me without disclosure of the disconnection. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11737207 — an unverified report by a vehicle owner.

POWER TRAIN

The Power Conversion System (PCS) in the Tesla Cybertruck is experiencing a high rate of hardware-level failure (specifically the PCS2 module) that poses three distinct safety risks beyond the loss of AC charging. Loss of Steer-by-Wire Integrity: The Cybertruck utilizes a full steer-by-wire system and a 48V low-voltage architecture. The PCS is responsible for managing the 48V bus and charging the LV battery. A hardware failure in the PCS (common alerts: PCS2_a094, PCS2_a137) threatens the stability of the 48V system. Any sudden collapse of the 48V bus while in motion could result in a total loss of steering control and vehicle maneuverability, creating an immediate risk of a high-speed collision. Loss of Propulsion and Stranding: PCS failure frequently leads to "limp mode" or a "no-start" condition where the vehicle cannot engage Drive or Reverse. Experiencing a loss of propulsion while in active traffic or being stranded on a highway shoulder without the ability to move the vehicle creates a severe life-safety hazard for occupants and other motorists. Failure of Visibility Systems: Critical safety components, including the primary windshield wiper and exterior lighting, are powered via the 48V system managed by the PCS. Hardware instability has led to reports of these systems failing during inclement weather, severely compromising driver visibility. Tesla has implemented software bypasses (OTA updates) to allow DC Supercharging when the AC hardware fails, but this is a "band-aid" that does not address the underlying hardware defect—likely MOSFET degradation. With replacement parts on backorder for 8+ weeks, owners are forced to operate vehicles with compromised electrical architectures. I am reporting this as a systemic hardware defect that requires an official safety recall.

NHTSA complaint #11734532 — an unverified report by a vehicle owner.

STEERING

The Power Conversion System (PCS) in the Tesla Cybertruck is experiencing a high rate of hardware-level failure (specifically the PCS2 module) that poses three distinct safety risks beyond the loss of AC charging. Loss of Steer-by-Wire Integrity: The Cybertruck utilizes a full steer-by-wire system and a 48V low-voltage architecture. The PCS is responsible for managing the 48V bus and charging the LV battery. A hardware failure in the PCS (common alerts: PCS2_a094, PCS2_a137) threatens the stability of the 48V system. Any sudden collapse of the 48V bus while in motion could result in a total loss of steering control and vehicle maneuverability, creating an immediate risk of a high-speed collision. Loss of Propulsion and Stranding: PCS failure frequently leads to "limp mode" or a "no-start" condition where the vehicle cannot engage Drive or Reverse. Experiencing a loss of propulsion while in active traffic or being stranded on a highway shoulder without the ability to move the vehicle creates a severe life-safety hazard for occupants and other motorists. Failure of Visibility Systems: Critical safety components, including the primary windshield wiper and exterior lighting, are powered via the 48V system managed by the PCS. Hardware instability has led to reports of these systems failing during inclement weather, severely compromising driver visibility. Tesla has implemented software bypasses (OTA updates) to allow DC Supercharging when the AC hardware fails, but this is a "band-aid" that does not address the underlying hardware defect—likely MOSFET degradation. With replacement parts on backorder for 8+ weeks, owners are forced to operate vehicles with compromised electrical architectures. I am reporting this as a systemic hardware defect that requires an official safety recall.

NHTSA complaint #11734532 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

The Power Conversion System (PCS) in the Tesla Cybertruck is experiencing a high rate of hardware-level failure (specifically the PCS2 module) that poses three distinct safety risks beyond the loss of AC charging. Loss of Steer-by-Wire Integrity: The Cybertruck utilizes a full steer-by-wire system and a 48V low-voltage architecture. The PCS is responsible for managing the 48V bus and charging the LV battery. A hardware failure in the PCS (common alerts: PCS2_a094, PCS2_a137) threatens the stability of the 48V system. Any sudden collapse of the 48V bus while in motion could result in a total loss of steering control and vehicle maneuverability, creating an immediate risk of a high-speed collision. Loss of Propulsion and Stranding: PCS failure frequently leads to "limp mode" or a "no-start" condition where the vehicle cannot engage Drive or Reverse. Experiencing a loss of propulsion while in active traffic or being stranded on a highway shoulder without the ability to move the vehicle creates a severe life-safety hazard for occupants and other motorists. Failure of Visibility Systems: Critical safety components, including the primary windshield wiper and exterior lighting, are powered via the 48V system managed by the PCS. Hardware instability has led to reports of these systems failing during inclement weather, severely compromising driver visibility. Tesla has implemented software bypasses (OTA updates) to allow DC Supercharging when the AC hardware fails, but this is a "band-aid" that does not address the underlying hardware defect—likely MOSFET degradation. With replacement parts on backorder for 8+ weeks, owners are forced to operate vehicles with compromised electrical architectures. I am reporting this as a systemic hardware defect that requires an official safety recall.

NHTSA complaint #11734532 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Front body panel of hood came unglued

NHTSA complaint #11719516 — an unverified report by a vehicle owner.

SUSPENSION

One to two times per month upon starting my Cybertruck I receive multiple notifications for systems not working including "Driver Assistance - Automatic Emergency Braking is unavailable" and "Steering & Braking - Adaptive ride control degraded/Ride comfort may be reduced." These alerts cause the disablement of the regenerative braking, auto-hold (braking), emergency braking, adaptive ride control, traction control, and the self drive features. While the vehicle is still drivable, my ability to control the vehicle is greatly diminished, as is the safety of the vehicle without any of the accident avoidance and stability systems working. After driving in this condition, if I park the vehicle, exit it, and let it sit for at least 10 minutes, all systems are normal upon reentry. On 1/5 I experienced this issue and opened a service request for warranty work and Tesla demanded that I agree to a $200 charge before they would even look at it and said if they were unable to see the issue then it would not be considered as warranty. Since I cannot reproduce this issue on demand I cancelled the service request as I do not want to pay them $200 to say they couldn't reproduce the issue. Internet searches have revealed that this is a common issue among Cybertrucks and despite multiple software updates since owning my vehicle, it has not gotten any better.

NHTSA complaint #11709187 — an unverified report by a vehicle owner.

LANE DEPARTURE: ASSIST

One to two times per month upon starting my Cybertruck I receive multiple notifications for systems not working including "Driver Assistance - Automatic Emergency Braking is unavailable" and "Steering & Braking - Adaptive ride control degraded/Ride comfort may be reduced." These alerts cause the disablement of the regenerative braking, auto-hold (braking), emergency braking, adaptive ride control, traction control, and the self drive features. While the vehicle is still drivable, my ability to control the vehicle is greatly diminished, as is the safety of the vehicle without any of the accident avoidance and stability systems working. After driving in this condition, if I park the vehicle, exit it, and let it sit for at least 10 minutes, all systems are normal upon reentry. On 1/5 I experienced this issue and opened a service request for warranty work and Tesla demanded that I agree to a $200 charge before they would even look at it and said if they were unable to see the issue then it would not be considered as warranty. Since I cannot reproduce this issue on demand I cancelled the service request as I do not want to pay them $200 to say they couldn't reproduce the issue. Internet searches have revealed that this is a common issue among Cybertrucks and despite multiple software updates since owning my vehicle, it has not gotten any better.

NHTSA complaint #11709187 — an unverified report by a vehicle owner.