159 of the 5,283 complaints filed about the Tesla Model S are about the body and structure — 3% of everything owners reported. The worst model year for it is 2015.
159
Complaints
3%
Share of all complaints
28
Crashes
3
Fires
STRUCTURE:BODY
Trunk latch fails, trunk latch safety mechanism also failed so manual release does not work. This is a safety issue
NHTSA complaint #11745960 — an unverified report by a vehicle owner.
STRUCTURE:BODY
2022 Tesla Model S Plaid purchased CPO from Tesla Florida Inc. Jacksonville on 8/29/2025 for $75,533.19. Multiple unresolved safety defects. (1) Trunk closure obstacle-detection failure 10/15/2025: key fob fell in gap between liftgate and roof; powered liftgate continued upward opening cycle and compressed fob against fixed roof glass until rear glass shattered. $4,100 repair. Same cycle on a child hand or finger would cause crush injury or amputation. Tesla Model X tailgate and falcon doors have obstacle detection; Plaid liftgate lacks it. (2) Passenger-side rear door handle requires extreme pressure to operate, raised 10/25/2025; iced over 1/19/2026 compounding egress hazard. (3) Center console haptic backup gear selector non-functional plus observed main touchscreen reset/blackout events: no manual gear control during foreseeable touchscreen failure event. (4) HV battery umbrella valves and flood port plunger required replacement 10/25/2025. (5) Rear spoiler bilaterally detached as of 5/13/2026 on 200mph-capable vehicle. (6) Front trunk latch unreliable; requires 2-3 commands to open; risk of hood opening at speed. (7) USB charging circuit melted a portable battery bank 11/2/2025; fire-risk overcurrent indicator. (8) Tire sidewall damage Tesla circled "OK" at CPO delivery; refused replacement 5 times; Tesla SMS 1/13/2026: "sidewall damage would need to be replaced." (9) Multiple unauthorized digital-access events: Track Mode created post-service; Charge Current set to 5A; Dog Mode disabled; pre-delivery key card 8/28/2025; phone key 3/14/2026; both front door reflectors found loosened 11/8/2025. Warranty defect notice sent certified 4/20/2026; Tesla declined 5/7/2026 without addressing any item. Full documentation, SMS thread, photographs attached.
NHTSA complaint #11737697 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The outside passenger front door handle stopped working and no longer allows the door to be opened from the outside. The handle does present and retract but does not respond when you pull it. This handle has been replaced once before by Tesla. Now, when the vehicle goes from being locked to unlocked the passenger front door pops open without any user interaction whatsoever.
NHTSA complaint #11724415 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Rear Door handles are inoperable again after repairs made by dealer. The fault is due to design fault with the wiring harness on the door handles. Manufacturer refuses to make repairs under warranty
NHTSA complaint #11721790 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The rear door handle has failed and now the door pops open when parked.
NHTSA complaint #11720129 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The retracting door handle on my Tesla Model S failed, creating a dangerous situation where I could not enter the vehicle when needed. This defect poses a serious safety risk because if this failure occurred during a medical emergency, a crash, or a fire, neither I nor first responders would be able to access the vehicle quickly. In real‑world scenarios — such as needing to reach a child in the back seat, assisting an injured passenger, or evacuating the vehicle in traffic — a non‑functional door handle can cause delays that lead to injury. The failure also increases risk in cold‑weather regions, where being locked out of the vehicle can expose occupants to freezing temperatures. This is not a cosmetic issue; it is a critical safety hazard.
NHTSA complaint #11709158 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The rear doors have emergency release cables in case the power is cut during a collision. These cables are hidden, not glowing, and have a small square pull on the end that is difficult to find and pull. I had great difficulty in testing the function to ensure the emergency cable pulls worked. They need to have a glowing T-handle on the end to facilitate location and movement, and the emergency cable location should be marked and visible in the car, just like the emergency hood and truck release are.
NHTSA complaint #11703010 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Tesla Model S 2021 Long Range: Upon closing the rear trunk close button from the app or close button on the hatch, the hatch goes down but won’t lock. It gives 3 beeps. Upon pressing open, it won’t go up and gives 3 beeps.
NHTSA complaint #11692785 — an unverified report by a vehicle owner.
STRUCTURE:BODY
On [XXX], I was driving my recently purchased 2018 Tesla Model S (VIN: [XXX], mileage approx. [30,536]). The vehicle was purchased directly through Tesla’s app in late August 2025 and delivered to me the same day of the incident. Approximately 4.5 hours after delivery, while driving with my son, white smoke began to come out of the cabin air vents. Within minutes, the smoke turned black and rapidly filled the interior of the car. I immediately pulled over and evacuated the vehicle with my son. Shortly after, the car caught fire and was completely destroyed. No modifications had been made to the vehicle, and it was sold to me as inspected and certified by Tesla. The sudden appearance of smoke from the vents and rapid escalation to a full vehicle fire posed a severe danger to me, my child, and others on the road. I am reporting this to NHTSA to document the incident and to request that the agency investigate whether Tesla Model S vehicles have underlying defects that may cause dangerous cabin fires shortly after use. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11686035 — an unverified report by a vehicle owner.
STRUCTURE:BODY
The wrap on the steering yoke is peeling, already had a steering yoke replacement 18 months ago under warranty, and this replacement steering yoke exibiting same peeling issue. Could be a safety grip issue as the yoke portion is more slippery at the peeled section. Tesla refuses to replace this faulty yoke as a covered safety item.
NHTSA complaint #11680563 — an unverified report by a vehicle owner.
STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS
The front right door top hinge bolts fell out. Believe the bottom one is broke off. Also have vehicle has a seat belt warning alarm indicated. There is a vehicle appointment scheduled for the Thursday August 14, 2025. Did not notice any warning signs. The door separated in the parking lot of a food establishment.
NHTSA complaint #11679777 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Front impact bumper separated from mount on one side due to rust. Noticed a noise from front of car when going over small bumps in the road. If we had been in an accident, the impact bumper would not have provided adequate protection for the passengers or vehicle components near the drivers front where the mount had separated from the bar. No other inspections have occurred. Pictures and info can also be found here: [XXX] Issue found during replacement of upper control arms. (image has an upper control arm that was removed from the same car at the same time with little/no rust) INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11671434 — an unverified report by a vehicle owner.
STRUCTURE:BODY:DOOR:HANDLE:INTERIOR
Driver door does not unlock after a trip, with passengers inside the vehicle. Driver is unable to exit the vehicle from the driver door. This has happened a couple times now, a Tesla mechanic stopped by after the first time, but didn’t find any issue. It’s happening again.
NHTSA complaint #11666652 — an unverified report by a vehicle owner.
STRUCTURE:BODY:DOOR:HANDLE:EXTERIOR
I parked my 2015 Tesla Model S and found the rear door on the passenger side would not open from the outside even though the door handle was extended. This is a safety concern as we could not open the door to remove our pet dog from the car. It would also not be possible to open the door from the outside to remove a child in a car seat next to the door or an elderly or disabled person sitting next to the door who is unable to open the door from the inside. This could be life threatening in the case of a car crash. It is a major safety defect that should be repaired at no cost by Tesla for the entire lifespan of the car. The problem persists and is reproducible.
NHTSA complaint #11664240 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Safety concern related to the tail lights and trunk lid lights on a tesla model s. I have had to replace both right and left turn lights and the trunk brake lights on multiple occasions due to water intrusion into the light housings. Water seepage over time or after heavy rains starts shorting the LEDs, thus causing safety concerns due to non-functioning tail lights. The vehicle has not been in an accident. It was purchased from a tesla "dealership" and they stated that there were no accidents. The car history report also indicates that the car has not been in an accident. There has been one attempted repair which added two drains to the trunk lid but the repair did not remedied the seepage into the light housing. There are reports online relating to water seepage into the light housings so its not just my car.
NHTSA complaint #11654008 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Front license plate holder is required in California. The bracket that holds the plate on the car is secured to the bumper with adhesive tape only. My bracket became loose, and thankfully we were able to retrieve the plate and bracket upon parking. This would have been an obvious hazard to us and other motorists if it fell off while on the street or highway. Tesla does not have any alternative solutions to fix or repair this issue and advised we purchase an aftermarket bracket. The front bracket on my car must be attached to meet NTSB safety standards.
NHTSA complaint #11652414 — an unverified report by a vehicle owner.
STRUCTURE:BODY:DOOR:HANDLE:EXTERIOR
I own a 2018 Tesla Model S. While it was still under warranty the passenger side door handle quit working and it was no longer possible to open that door. Tesla replaced the door handle at no change with a newly designed mechanism. It was explained to me that they redesigned the mechanism which had a high failure rate, and my car handles would no longer be installed in later cars. I asked if they would change all 4 door handles for me, and was told they would not. Now several years later, another door handle has failed. This time dangerously. The door pops open spontaneously, and therefore the car is not safe to drive. I have an appointment for repair, but at full cost. Should Tesla not cover the cost, as it makes the vehicle unsafe to drive, and they clearly knew about it when they originally sold me my car?
NHTSA complaint #11647218 — an unverified report by a vehicle owner.
STRUCTURE:BODY
Drivers door handle failed to operate, occupant was locked out of vehicle, safety of operator was compromised as elderly operator has to climb over passenger and center console to enter drivers area. Problem is ongoing as door handle will not operate at all. Vehicle has not been inspected yet. No symptoms, door handle failed and cannot be opened from the outside at all.
NHTSA complaint #11636859 — an unverified report by a vehicle owner.
STRUCTURE:BODY
When parked and opening the drivers door or rear passenger doors, the front passenger door will unlatch. Something is setting off the relay to open the front door when other doors open. Does not happen 100% of the time, but 50%+
NHTSA complaint #11618483 — an unverified report by a vehicle owner.
STRUCTURE:BODY
I own Tesla model S 2018. Last week in Florida there was a storm near the place where I live, (Tampa). I happen to drive in the flooded road only to realize that Tesla has a known manufacturing defect, which multiple customers have posted on the Internet about, related to seal in the trunk, which basically causes the flood water to enter into the trunk, I noticed that a lot of model S Tesla users are going through this issue but Tesla has failed to recall the car and provide a fix. Tesla is demanding that the customers pay for this fix, for cars which are out of warranty even though this is a quality/manufacturing issue. I Urge you to take action and provide a solution.
NHTSA complaint #11608255 — an unverified report by a vehicle owner.