57 of the 1,693 complaints about the 2018 Tesla Model 3 are about the body and structure — 3% of everything reported for this model year. Half of the failures with a mileage on record happened before 16,000 miles.
57
Complaints
16
Crashes
1
Fires
8
Injuries
Filed with NHTSA, in their own words.
STRUCTURE:BODY
The door handles have a defect. The chrome peels off unexpectedly, outside of normal wear and tear, and may cause a deep cut to a person’s finger. It cut my son’s finger, causing bleeding. After researching, I found online that that this has happened to many other people.
NHTSA complaint #11740487 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The front lateral links, compliance links, and stabilizer bar link on my 2018 Tesla Model 3 Long Range failed and required replacement in January 2026. Prior to failure, abnormal creaking and clunking noise from the front suspension began appearing weeks before the repair — no warning lights illuminated at any point. The failed components were replaced by a Tesla-certified Service Center and are no longer available for inspection. The failure was confirmed and repaired solely by the Tesla Service Center; no police, insurance representatives, or other parties inspected the vehicle. I was charged out of pocket for this repair. The lateral link separation risk directly endangers vehicle safety — if a fastener loosens sufficiently, the lateral link can detach from the subframe, causing sudden wheel misalignment and loss of steering control, which could result in a crash at any speed. Tesla issued recall 23V-235 (NHTSA campaign 23V235000) in March 2023 for this exact condition on 2018-2019 Model 3 vehicles. My vehicle's VIN was not included in the recall population, yet experienced the identical failure mode. I am requesting this complaint be considered for recall expansion under 23V-235 and seeking reimbursement for out-of-pocket repair costs for a defect Tesla has already acknowledged in identical vehicles.
NHTSA complaint #11732882 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Following a professional suspension repair at a Tesla Service Center, critical underbody fasteners (bolts) became loose, causing the aero shield to sag and creating a potential road hazard. Upon inspection, the service technician confirmed the bolts were unsecured. The failure of these fasteners on a safety-critical system poses a risk of parts detaching while in motion or loss of vehicle control. The service center refused to acknowledge this as a workmanship failure under the 12-month repair warranty, despite the fasteners being last serviced by their technicians.
NHTSA complaint #11730896 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The chrome trim on exterior door handle on driver side failed, peeling back to create a sharp, blade-like edge. When i tried opening the door, it sliced my finger causing bleeding and a trip to urgent care. Aparently many other consumers are facing the same problem. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11727386 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The rear doors are not equipped with manual door releases. In the event of a crash or fire the rear seat passengers would be trapped and would only be able to exit over the front seats and front seat passengers. If the front doors were damaged or front passengers incapacitated the egress for the back seat passengers would be severely impacted. If a fire would occur the situation would be exacerbated. Tesla corrected this condition in later models by installing cable releases for the rear doors. Tesla has not responded with any positive response to our request to provide an upgrade and manual rear door releases.
NHTSA complaint #11716455 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Hello, I have a Tesla model 3 that I bought back in 2018 . On [XXX] when I sliced my finger while opening the door, because the chrome coating on the door handle started peeling. The cut was very deep ( see attached pictures). I contacted Tesla for resolution and they said that the car is not under warranty and I have to pay $340 for each handle to replace them. Apparently the peeling chrome happened to many other Tesla 3 owners and the company is aware of it and they told me that it might be caused by the car washing detergent (?!!) I think it was a defective design and the peeling chrome coating is a major health hazard. The child cand slice their fingers and if person has a bleeding issues and cut themselves while on the road it can be bad. I think it should be treated as a recall for bad design and should be fixed for free. I lost couple of days of work since I work in the Operating room and my finger was severely cut. I will wait for your response, thank you, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11703600 — an unverified report by a vehicle owner.
STRUCTURE
The contact owns a 2018 Tesla Model 3. The contact stated that while driving approximately 60 MPH, the vehicle became difficult to maneuver. No warning lights were illuminated. The vehicle was taken to a dealer, where it was diagnosed, and determined that the frame underneath the vehicle was fractured. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 89,700.
NHTSA complaint #11696856 — an unverified report by a vehicle owner.
STRUCTURE:FRAME AND MEMBERS
The contact owns a 2018 Tesla Model 3. The contact stated that on several occasions while making left or right turns, there was a loud clanking noise emanating from the front of the vehicle. The vehicle was taken to a dealer to be diagnosed. The contact was informed that the lower control arm bushings had deteriorated and needed to be replaced. The vehicle was not repaired. The vehicle was taken to the dealer several months later where it was diagnosed that the bushings and one of the well nuts had sheared off, and the subframe needed to be replaced. The manufacturer was notified of the failure. The failure mileage was approximately 40,000.
NHTSA complaint #11633652 — an unverified report by a vehicle owner.
STRUCTURE:BODY
I took my car in to Tesla to have the tires replaced, during the service appointment my frunk was opened and closed by the technicians. Within ten miles of leaving the dealership my hood/frunk flew open and broke my windshield and frunk hood
NHTSA complaint #11628995 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The driver's side rear door handle is defective. The chrome wrap around the door handle is I believe aluminum that does not adhere properly to the plastic handle, resulting in the wrap coming loose and have caused cuts to the fingers of unaware passengers. Tesla has requested $350 to fix what is an obvious safety hazard. Others are discussing this online: [XXX] [XXX] The online reports always call out that it's the same door - rear driver's side - indicating to me an installation flaw. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11616060 — an unverified report by a vehicle owner.
STRUCTURE:BODY:DOOR:HANDLE:EXTERIOR
The contact owns a 2018 Tesla Model 3. The contact stated that the chrome trim became loose on all four doors, which caused injuries to the contact and daughter while opening the doors. The vehicle was diagnosed by an onboard App, that determined that all four door handles needed to be replaced. The vehicle was not repaired. The contact stated that it was a known issue since the manufacturer had changed the chrome trim for the newer model vehicles. The manufacturer was made aware of the failure, and informed the contact that he had to pay out of pocket for the repairs. The failure mileage was approximately 30,000.
NHTSA complaint #11589683 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The 2018 Tesla model 3 has no manual release for rear passenger doors. Rear doors often fail to open due to door panel alignment or actuator for door. Doors will feel like they are opening but will be stuck. passenger will be unable to exit the rear of the vehicle incase of fire, power loss or due to an accident with no ability to exit the rear of the vehicle.
NHTSA complaint #11583984 — an unverified report by a vehicle owner.
STRUCTURE:BODY
There are 2 separate issues with our door handles. The first issue is that they are slow to retract, and in the cold, the often remain in an open position. This has happened numerous times over this winter when my child gets in her car booster. The second issue relates to the method in which tesla adhered the chrome to the handles. There is a small seam on the bottom of the handle that peals off, This results in a VERY sharp metallic layer on the handle. I have now sliced my hand twice on this handle. (I’ve scheduled Tesla to replace this handle. Unfortunately this is coming at a cost to me as the consumer.
NHTSA complaint #11581007 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The rear bumper fell off on [XXX] on the [XXX] of the [XXX] bound for [XXX] toward Long Beach Airport when driving in the rain through a puddle of water. It’s a serious safety hazard for the model 3 and the cars behind. This is a widely reported known design flaw, but Tesla refused to cover the repair cost. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11569452 — an unverified report by a vehicle owner.
STRUCTURE:BODY:BUMPERS
The rear bumper fell off on [XXX] on the [XXX] of the [XXX] bound for [XXX] toward Long Beach Airport when driving in the rain through a puddle of water. It’s a serious safety hazard for the model 3 and the cars behind. This is a widely reported known design flaw, but Tesla refused to cover the repair cost. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11569452 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Vehicle will randomly lock various doors and not allow them to be opened from the outside unless they are first opened from the inside and then the car will allow the extrnal handle to be used to open the door. This has happened on the passenger side front and rear and on the driver side rear door.
NHTSA complaint #11521246 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Car speed control malfunctioned. There was a sudden acceleration when car was below 10 miles in the parking lot. The driver lost control on braking and car keep accelerating even no force was applied to pedal. Dribe had to steer out of parking lot and crash through a wood en fence on next door neighbor. Car still keep going thru front yard of two houses cross the street and eventually hit a concrete barrier on front porch of the house. Several parts breakoff underneath the car , fluid leaked and all wheels are severely damage. Severy damage to front body side of the of the car and battery system , has occurred . There was near miss body injury to pedestrians in the area and neighbor hood. No physical injury was reported at the time of accident. but driver reported psychologycal distress. Currently CAR is towed away per Instruction from Insurance company for evaluation. Police report CASE# 23021162 NORTH bRUNSWICK pd 710 hermann road North Brunswick, NJ 08902
NHTSA complaint #11518603 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Auto was in reverse and moved backwards while rear rt side door was open causing damage to another auto parked alongside. Shouldn't the auto not move in gear when a door is open and unlatched ? The auto can move forward or back with any door that remains open. I thought this would be a safety issue
NHTSA complaint #11512959 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Rear left exterior door handle. Peeling chrome plating on the under side of handle creates a sharp ragged edge that cuts fingers. The ragged edge also prevents the handle from retracting completely into the door, which may affect secure closure of the door. Reported to Tesla, who declined to cover the repair and sent me an estimate of $270 for parts and labor to replace the door handle.
NHTSA complaint #11504433 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Read passenger subframe bolt fell out while driving. The subframe of my vehicle and the mounting plate had a 3 inch gap between it. It made the rear end shake and loose control at speed. Tesla refused to give me torque specs twice. I was able to find service manual online and re-torque it. There was no locktite on the bolt. There was no warning, just a metal clanking noise and then the vehicle became dangerous to drive.
NHTSA complaint #11504067 — an unverified report by a vehicle owner.
STRUCTURE:BODY
I was driving the car about 35-40 MPH when I heard a popping sound. The steering immediately locked up and the car was undrivable and unsteerable. I looked around car and the body of the car was resting on top of the front right passenger side tire. A bolt was found underneath the car. There were no vehicle system warnings, I did not hit anything, nor has the car been in any accidents. The car could not even be put into neutral or moved out of the 4 lane road. I contacted police and tow truck who said swing arm had failed. I had four children in the car who could have been seriously or fatally injured. Tesla has been contacted but said it isnt their problem or a manufacturing problem although there is lots of reports on internet and they have issued a recall for this very problem on other models. I am very concerned about this safety issue that needs to be addressed since it is potentially very dangerous.
NHTSA complaint #11502185 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The front Undercarriage/ Aero Tray on My Model 3 started to tear apart after driving in the rain on the freeway. This is a part of the existing SB-19-12-001 Tesla Service Bulletin. While driving on the freeway on a rainy day in Los Angeles, I heard the undercarriage tray start dragging on the freeway. Did not hit or run over any objects to cause the tray to rip. Contacted Tesla and showed Tesla several photos along with the service bulletin affecting 2017-2018 Model 3’s which my Model 3 is a August 2018 Build and Tesla did not want to honor the Service bulletin and they wanted to charge me $441 for replacing both front and back Aero trays. This needs to be reported that Tesla Service centers are not honoring Service bulletins about defective parts. This can be a safety issue, if the part we’re to rip off and hit another car and cause an accident, it can be avoided if tesla honors the service bulletin.
NHTSA complaint #11499770 — an unverified report by a vehicle owner.
STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS
The contact owns a 2018 Tesla Model 3. The contact stated that while driving at an undisclosed speed, he heard a rattling noise underneath the vehicle. The contact stated that upon inspection, he noticed that the underbody shield had detached. No warning light was illuminated. The dealer was not notified of the failure. The manufacturer was notified, and the contact was informed to submit photos and a virtual diagnosis was performed. The failure mileage was approximately 39,000.
NHTSA complaint #11497076 — an unverified report by a vehicle owner.
STRUCTURE:BODY
My vehicle, was parked and pulled out of the parking lot on a doing a complete left steering turn, couple of nuts&bolts carrying the vehicle control arm fell to the ground and the entire control arm disengaged out of the shafts. This could have been very fatal, if my family or me were riding the car. Tesla was trying to tell me that saying that, this is caused due to a high impact etc, not doing wheel alignment etc. And they want to charge me $3561+ to fix this shaft to put back the nuts and bolts that fell off from the car.
NHTSA complaint #11489482 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Rear under carriage shield gets pulled off under normal driving conditions and rips off the bumper cover and rear wheel wells
NHTSA complaint #11446734 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The contact owns a 2018 Tesla Model 3. The contact stated that the vehicle had begun swaying while driving approximately 60 MPH. Additionally, the contact noticed a creaking noise coming from underneath the vehicle. The contact pulled into a parking lot and the vehicle suddenly stalled. The contact noticed that the control arm had detached. The vehicle was towed to the dealer but was not yet diagnosed. The vehicle was not repaired. The manufacturer and dealer were informed of the failure. The approximate failure mileage was 33,000.
NHTSA complaint #11445981 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The steering system failed. I'm not sure about the availability for inspection. My safety was put at risk when my car collided with another car. I had just pulled out of my driveway and turned to go down the street a short distance from a stop sign where I would turn left. From a video taken by one of the car's cameras, the car went to the left side of the street and started toward the intersection where the car hit another vehicle. I have driven to the intersection numerous times. There is no way that I would have pulled toward the left side of the street. I believe that something in the steering system malfunctioned. This put me and other drivers on the road at risk. I don't know if the the problem has reproduced. There was a policeman at the site, but he would not inspect the vehicle for a malfunction. My insurance company must have inspected the car as they called today to inform me that the car is totaled. The failure happened so quickly, that I had no warning.
NHTSA complaint #11445624 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The 12V auxiliary battery failed around 6:45pm PST on Aug. 8, 2021, causing the car to be unresponsive - Tesla acknowledged this. There was no warning prior to the battery failure. The driver (my wife) was trapped in the car because the electronic door latch would not open and the windows would not retract. My wife was panicked, crying and kicking at the window. I had to break the window to get her out. Tesla replaced the 12V battery as an item under warranty. They believe that I/we should have know about the manual door release to avoid breaking the window. This manual release is unmarked and inconspicuous. Tesla claims that the manual door release is described in the car's user manual; however, the car's user manual is electronic (no hard copy provided) and was not accessible because the car was unresponsive. The user manual can only be accessed from the car's display screen. There is no telephone number to call a Tesla representative and no way to access the user manual via the iPhone application. I had no choice but to break the window. Tesla is aware that their 12V batteries are failing prematurely and are not doing anything to prevent drivers from being trapped inside vehicles. The tow truck driver said he picked up four Tesla cars on Aug 9th for the same battery issue. I spoke to multiple other Tesla owners and none were aware of the manual door release. This includes one of my neighbors who received his Tesla a few months ago. It was not explained during the delivery process. The driver must rely on an electronic user's manual that can only be accessed when the car is operational. The faulty battery creates a condition that renders the car non-operational, so the contents of the user manual are irrelevant. Furthermore, the unmarked door release is an insufficient safety feature. Airplanes, buses, trains all have emergency exits marked. Apparently Tesla chose not to do this. Tesla created an unsafe situation where people can be trapped.
NHTSA complaint #11428766 — an unverified report by a vehicle owner.
STRUCTURE:BODY
On May 28, 2021 I took my Tesla Model 3 in to have the undercarriage replaced after it came into contact with water and started to separate from the car. Tesla replaced both the front and rear aero shield panels under warranty. I was told this should not happen again as this part is an upgraded version from the original part. Seven days later, the same issue occurred where the part began to separate from the vehicle. This is a potential safety hazard for other drivers if it is not observed to be separating, it can fall off completely and become a flying object or road debris causing an accident for others.
NHTSA complaint #11419643 — an unverified report by a vehicle owner.
STRUCTURE:BODY
My car was parked and was charging in our garage when it suddenly shut off. I got into the car to get something, but noticed the car's computer screen did not light up. I tried to open the glove box and it also would not open. When I tried to open the car door button, it also would not open the door while I was still inside. I got out of the car using the manual car handle and realized the charger would not unplug from the car either. I was very scared that the car was going to burn because the battery was charging at the time and everything suddenly happened. In addition, the backseat doors do not have a manual car handle to open the door. In an event of an emergency and the power shuts off, how are passengers sitting in the backseat going to escape from the vehicle??? The cause was due to a 12v battery malfunction.
NHTSA complaint #11419435 — an unverified report by a vehicle owner.