What 459 owners told NHTSA about the 2013 Tesla Model S P90d

HERE IS AN AUCTION LISTING OF A TESLA THAT HAS CAUGHT FIRE. HTTP://SALVAGE-BID.COM/RESULT.PHP?VIN=[XXX] THE PJHOTOGRAPHS SHOW THAT THE LH TOP BALL-JOINT HAS PULLED OUT FROM THE STEERING KNUCKLE. THIS IS NOT THE RESULT OF THE FIRE BECAUSE THOSE PARTS ARE SOLID METAL AND NEITHER THE STEERING KNUCKLE NOR THE WISHBONE HAVE MELTED. THE SUSPENSION FAILURE IS CONSISTENT WITH THE PATTERN OF SIMILAR FAILURES THAT APPEAR TO HAVE BEEN THE CAUSE OF CRASHES. PLEASE INVESTIGATE THIS RECURRING FAILURE INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI 10897285

I HAVE SUPPLIED NHTSA WITH DETAILS OF MANY TESLAS WITH BROKEN SUSPENSIONS. THIS LATEST ONE THAT HAS JUST ARRIVED IN THE WRECKING YARD IS A PRIME EXAMPLE. HTTPS://M.IAAI.COM/VEHICLEDETENC.ASPX?AUCTIONID=21270046&ITEMID=22443933&ROWID=7&PAGESOURCE=VEHICLERESULTS PLEASE LOOK AT THE PHOTOGRAPHS AND SEE IF YOU AGREE THAT THERE IS A REAL PROBLEM WITH THE DESIGN AND MANUFACTURE OF THESE CARS. TWO OF THE WHEELS AND TIRES HAVE BEEN BADLY DAMAGED WHILST THE CAR WAS IN MOTION. IT APPEARS THAT THE AIR SUSPENSION HAS FAILED CAUSING ALL WHEELS TO JAM UP INTO THE WHEEL WELLS. OWNERS HAVE REPORTED THAT THE CAR DOES NOT HAVE LIMIT STOPS AND THIS IS WHY A SIMPLE AIR LEAK CAN RESULT IN DISASTER. HTTPS://FORUMS.TESLA.COM/EN_AU/FORUM/FORUMS/AIR-SUSPENSION-FAILURE-VERY-UNPLEASANT-RESULTS

NHTSA ODI 10895847

HERE IS A REPORT OF A TESLA CRASH AT AN INTERSECTION. HTTP://INSIDEEVS.COM/TESLA-MODEL-S-GETS-WRECKED-OWNER-SAYS-VEHICLE-SAVED-HIS-LIFE-IMAGES-OWNER-TESTIMONIAL/ THE REPORT BLAMES THE OTHER DRIVER AND CREDITS THE TESLA WITH SAVING THE OWNER FROM INJURY. THE CLAIM THAT THE HYUNDAI HIT THE TESLA AND THEN REBOUNDED AND HIT THE TESLA ONCE MORE IS QUITE UNUSUAL. THE PHOTOGRAPHS ARE HIGH RESOLUTION AND IF THEY ARE BLOWN UP AND EXAMINED CLOSE UP YOU CAN SEETHE THAT TIP OF THE STEERING KNUCKLE IS BROKEN OFF (CLOSE UP PHOTOGRAPH OF THE ACTUAL PART -WHICH WAS PURCHASED BY A REBUILDER- HERE: HTTPS://WWW.FLICKR.COM/PHOTOS/136377865@N05/22799472895/IN/ALBUM-72157658490111523/ I THINK IT IS POSSIBLE THAT SUSPENSION FAILURES ARE CAUSING MANY CRASHES. THE DATE OF THE INCIDENT IS AN ESTIMATE. THE OWNER SAYS THAT TESLA HAVE BEEN VERY HELPFUL. "?TESLA CALLED MY HOME SHORTLY AFTERWARDS SAYING THAT THEY RECEIVED MULTIPLE ALARMS FROM THE CAR AND WANTED TO MAKE SURE I WAS OK. THEY PICKED UP MY CAR FREE OF CHARGE AND TRANSPORTED IT 50 MILES TO THE NEAREST SERVICE CENTER. THEY ARE ALSO ARRANGING A LOANER MODEL S. CAN I ASK FOR MORE? PLEASE NOTE THAT I AM NOT THE OWNER JUST A CONCERNED CITIZEN PLEASE INCLUDE THIS CRASH IN ANY INQUIRY INTO THE TESLA SUSPENSION ISSUE. *TR

NHTSA ODI 10894694

HERE IS ANOTHER CRASHED TESLA IN THE JUNK-YARD. HTTP://WWW.COPART.COM/US/LOT/26133286/PHOTOS?SEARCHID=978872155 THE FRONT WHEEL HAS COME OFF AND IT HAS THE USUAL CHARACTERISTICS OF A GROOVE WORN IN THE TREAD AND THE TIRE PARTLY PEELED OFF THE RIM. THIS IS (IMHO) MOST LIKELY TO HAVE OCCURRED WHILE THE CAR WAS IN MOTION AND BEFORE THE MAIN IMPACT. IT IS LIKELY THAT THIS WAS THE CAUSE OF THE CRASH AND NOT MERELY THE RESULT OF THE CRASH. THERE SEEM TO BE FAR TOO MANY SIMILAR CASES OF SUSPENSION FAILURE. PLEASE INVESTIGATE. PLEASE NOT THAT I AM NOT THE OWNER, JUST A CONCERNED CITIZEN. THE REPORTS OF NUMBER OF PERSONS INJURED ARE ONLY AN ESTIMATE BASED ON THE SEVERITY OF THE CRASH.

NHTSA ODI 10884408

AT 45K MILES MY SUSPENSION FAILED. IT REQUIRED A NEW CONTROL ARM AND SUSPENSION ALIGNMENT. TESLA SAID "DROVE VEHICLE AND CONFIRMED NOISE FROM FRONT OF VEHICLE. UPON INSPECTION FOUND LEFT FRONT UPPER CONTROL ARM JOINT TO HAVE EXCESSIVE FREEPLAY." THE INDIVIDUAL AT TESLA SAID IT WAS NO BIG DEAL. I WAS DRIVING THE CAR AND HEARD A CRACK NOISE WHILE GOING DOWN A STREET. FROM THEN ON OUT MY CAR MADE LOUD SQUEAKING AND CRACKING NOISES.

NHTSA ODI 10873808

HERE IS A 2013 TESLA FRESHLY ARRIVED IN THE SALVAGE YARD. HTTP://WWW.COPART.COM/US/LOT/24523446?SEARCHID=1172082716 THE BACK RH WHEEL AND SUSPENSION IS COMPLETELY TORN OFF THE CAR. THERE IS SOME IMPACT DAMAGE BUT THAT IS PROBABLY THE RESULT OF THE THE SUSPENSION FAILURE . THERE ARE SO MANY EXAMPLES OF THIS KIND OF FAILURE IN THE TESLA THAT IT POINTS TO THERE BEING A DESIGN/MANUFACTURING DEFECT. TESLA HAS REQUIRED SOME OWNERS TO SIGN NON DISCLOSURE AGREEMENTS POSTERS ON TESLA FORUMS ARE DISCOURAGING OWNERS FROM REPORTING THESE PROBLEMS AND ARE EVEN ALLEGING THAT THESE COMPLAINTS ARE FRAUDULENT. MY COMPLAINTS ARE HONEST REPORTS WITH VERIFIABLE DATA TO SUPPORT THEM. IF YOU REQUIRE SAMPLES OF BROKEN SUSPENSION PARTS THEN ALL YOU HAVE TO DO IS VISIT THE SALVAGE AUCTION YARDS. PLEASE INVESTIGATE THE MULTIPLE FAILURES OF TESLA SUSPENSIONS TO SAVE LIVES.

NHTSA ODI 10873289

HERE IS ANOTHER MODEL S FOR SALE AS A SALVAGE WRECK HTTP://WWW.COPART.COM/US/EN/LOT/24419056?SEARCHID=213897253 THE FRONT LH TOP BALL JOINT HAS SEPARATED FROM THE STEERING KNUCKLE AND THERE IS NO COLLISION DAMAGE FORWARD OF THE WHEEL THAT WOULD HAVE CAUSED THIS FAILURE. THE CAR HAS THEN CAUGHT FIRE AND BURNED OUT. THIS BALL JOINT FAILURE LOOKS VERY SIMILAR TO THE OTHER 2013 INCIDENT WHICH HAS ALREADY BEEN LISTED ON YOUR DATABASE. DATE COMPLAINT FILED: 04/28/2016DATE OF INCIDENT: 04/24/2016COMPONENT(S): STEERING , SUSPENSIONNHTSA ID NUMBER: 10862066CONSUMER LOCATION: CONNELLSVILLE, PA ALL PRODUCTS ASSOCIATED WITH THIS COMPLAINT EXPAND DETAILS CLOSE HELP 0 AVAILABLE DOCUMENTS CRASH:NO FIRE:NO NUMBER OF INJURIES:0 NUMBER OF DEATHS:0 MANUFACTURER: TESLA MOTORS, INC. VEHICLE IDENTIFICATION NO. (VIN): P09340... SUMMARY: MY FRONT WHEEL HUB ASSEMBLY CAME LOOSE FROM THE UPPER CONTROL ARM CAUSING A LOSE OF STEERING. HERE IS A YOUTUBE VIDEO OF THAT BADLY WORN BALL-JOINT HTTPS://WWW.YOUTUBE.COM/WATCH?V=DGDKZMLZQOG THERE MUST BE MANY TESLAS ON THE ROADS WITH THESE BALL-JOINTS READY TO FALL APART. NO WARNING HAS BEEN ISSUED TO OWNERS. PLEASE INVESTIGATE

NHTSA ODI 10871985

ANOTHER TESLA IN THE SALVAGE YARD HTTPS://M.IAAI.COM/VEHICLEDETENC.ASPX?AUCTIONID=0&ITEMID=22102447&ROWID=30&PAGESOURCE=VEHICLERESULTS FRONT SUSPENSION COMPLETELY TORN OFF, NO DAMAGE FORWARD OF THE WHEEL THAT WOULD ACCOUNT FOR THE DAMAGE. THE TOP BALL-JOINT STEM HAS PULLED OUT OF THE TOP OF THE STEERING KNUCKLE WHICH HAS A FRACTURED TIP. THERE ARE FAR TOO MANY OF THESE FAILURES FOR THE RELATIVELY SMALL NUMBER OF THESE CARS THAT ARE ON THE ROADS PLEASE INVESTIGATE.

NHTSA ODI 10871990

I AM FILING THIS COMPLAINT IN THE HOPE THAT YOU WILL BE ABLE TO SEE THERE IS A CLEAR PATTERN OF FAILURE IN THE TESLA ALLOY SUSPENSION COMPONENTS. THIS CAR HAS THE ENTIRE LH BACK SUSPENSION RIPPED OUT. HTTPS://M.IAAI.COM/VEHICLEDETENC.ASPX?AUCTIONID=0&ITEMID=22060456&ROWID=30&PAGESOURCE=VEHICLERESULTS THE ONLY DAMAGE TO THE CAR IS WHERE THE WHEEL HAS EXITED THROUGH THE BACK BUMPER. PLEASE INVESTIGATE TO PREVENT LOSS OF INNOCENT LIVES.

NHTSA ODI 10870904

THIS MODEL S HAS JUST ARRIVED AT THE WRECKER'S YARD. HTTPS://M.IAAI.COM/VEHICLEDETENC.ASPX?AUCTIONID=0&ITEMID=22105984&ROWID=32&PAGESOURCE=VEHICLERESULTS# ONCE AGAIN THE REAR SUSPENSION HAS BEEN WRENCHED OFF THE CAR WITHOUT ANY SIGN OF COLLISION DAMAGE THAT WOULD HAVE CAUSED THE FAILURE. THE MOTOR HAS PLENTY OF TORQUE TO WRENCH OFF THE SUSPENSION. THERE IS A CLEAR PATTERN OF FAILURE. PLEASE INVESTIGATE.

NHTSA ODI 10870133

HERE IS YET ANOTHER TESLA MODEL S FOR SALE AS A SALVAGE WRECK. HTTPS://M.IAAI.COM/VEHICLEDETENC.ASPX?AUCTIONID=0&ITEMID=22060456&ROWID=28&PAGESOURCE=VEHICLERESULTS# THE LH REAR WHEEL AND SUSPENSION HAVE TORN OUTWARDS THROUGH THE BODYWORK. THE RH WHEEL IS TILTED OVER AT AN ANGLE. THERE IS NO IMPACT DAMAGE THAT WOULD HAVE CAUSED THIS. THERE HAVE BEEN DOZENS OF SIMILAR INCIDENTS. HTTPS://WWW.FLICKR.COM/PHOTOS/136377865@N05/SETS/72157658490111523/ OWNERS ARE BEING ASKED TO SIGN NDA,S IN EXCHANGE FOR GOODWILL PAYMENTS. THE WORDING OF THE NDA CAN BE INTERPRETED TO MEAN THAT THEY SHOULD NOT EVEN REPORT THE INCIDENT TO NHTSA PLEASE INVESTIGATE THIS MATTER. *TR

NHTSA ODI 10865907

HERE IS ANOTHER TESLA WITH A COLLAPSED FRONT SUSPENSION. HTTP://WWW.COPART.COM/US/EN/LOT/21054696?SEARCHID=632075351 THE CAR HAS NOT BEEN INVOLVED IN A COLLISION, THE FRONT SUSPENSION HAS SIMPLY FALLEN APART. THE FRONT WHEEL IS SLICED NEARLY IN HALF BY A BROKEN SUSPENSION COMPONENT. THIS TYPE OF FAILURE CAN BE SEEN IN MANY ACCIDENTS INVOLVING TESLAS. PLEASE LOOK AT THE PATTERN HERE. THE ALLOY SUSPENSION LINKS ARE WEAK. THE STEERING-KNUCKLE HAS BEEN REDESIGNED AND MADE STRONGER FROM 2015 ONWARDS BUT NOTHING HAS BEEN DONE ABOUT THE OLDER MODEL CARS. EVEN THE NEW AND STRONGER SUSPENSIONS ARE STILL SNAPPING OFF THE CARS. CUSTOMERS ARE BEING FORCED TO SIGN NON DISCLOSURE AGREEMENTS IN EXCHANGE FOR GOODWILL PAYMENTS. PLEASE INVESTIGATE.

NHTSA ODI 10863852

YOU HAVE A COMPLAINT LISTED FOR A SNAPPED FRONT SUSPENSION ( REF # 10862066) THERE IS A DISCUSSION THREAD HERE HTTPS://TESLAMOTORSCLUB.COM/TMC/THREADS/SUSPENSION-PROBLEM-ON-MODEL-S.69204/ WHICH SHOWS A TOP BALL JOINT THAT HAS BEEN CORRODED SO BADLY THAT IT HAS POPPED OUT OF THE SOCKET. POSTERS ARE SAYING THAT SIMILAR CASES HAVE HAPPENED IN NORWAY AND OTHER PLACES THAT USE SALT ON THE ROADS. THE DESIGN OF THE MODEL S ALLOWS ROAD DIRT TO BE THROWN ON TO THE SUSPENSION PARTS. IN THE THREAD THERE ARE PHOTOGRAPHS OF TESLAS WITH HEAVY CORROSION. IT IS LIKELY THAT GALVANIC CORROSION IS OCCURRING. ALUMINIUM AND STEEL COMPONENTS ARE IN DIRECT CONTACT WHICH WILL CAUSE CORROSION IN WET AND SALTY CONDITIONS. IN NORTHERN USA,CANADA, NORWAY AND MANY OTHER COUNTRIES SALT IS USED ON THE ROADS. THIS FAULT WAS NOT PICKED UP UNTIL IT ACTUALLY FELL APART AND THE SERVICE DEPARTMENT FOUND THAT BALL JOINTS ON BOTH SIDES OF THE CAR NEEDED REPLACING. THIS IS A DANGER TO OWNERS AND TO OTHER ROAD USERS. PLEASE INVESTIGATE.

NHTSA ODI 10862640

MY FRONT WHEEL HUB ASSEMBLY CAME LOOSE FROM THE UPPER CONTROL ARM CAUSING A LOSE OF STEERING.

NHTSA ODI 10862066

LEFT REAR SUSPENSION INTEGRAL LINK COMPLETELY BROKE AND THE ATTACHED PIECE LODGED IN THE INSIDE OF THE TIRE RIM CAUSING MAJOR DAMAGE TO THE TIRE RIM. *TR

NHTSA ODI 10714213

WAS REPLACING THE LEFT REAR WHEEL AND NOTED AN ODD "NOTCH" IN THE LEFT REAR SUSPENSION ALUMINUM UPPER CONTROL ARM. CLOSER INSPECTION REVEALED THAT THE UPPER CONTROL ARM WAS PARTIALLY SEVERED WITH APPROXIMATELY 1/2 OF THE LOWER PORTION CROSS SECTION, AND 1/3 TO 1/4 OF THE UPPER PORTION CROSS SECTION, CUT THROUGH BY THE LOWER SHOCK ABSORBER ATTACHMENT BOLT. IT APPEARS THAT THE BOLT WAS MOUNTED BACKWARDS, WITH THE SHARP TIP OF THE BOLT FACING FORWARD INSTEAD OF REARWARD, AT EITHER THE FACTORY, OR WHEN THE POWERTRAIN WAS REPLACED BY THE TESLA DENVER SERVICE CENTER (AS REPORTED BY THE PREVIOUS OWNER). EXTENSIVE PHOTOGRAPHS ARE AVAILABLE AND, FRANKLY, THEY ARE ESSENTIAL TO ACCURATELY DEPICT THE SERIOUS AND POTENTIALLY CATASTROPHIC NATURE OF THIS SUSPENSION DAMAGE. IT WOULD APPEAR THAT THE UPPER CONTROL ARM, A MAJOR SUSPENSION COMPONENT WHOSE FAILURE WOULD LIKE RESULT IN A LOSS OF VEHICLE CONTROL AND POSSIBLY A ROLLOVER ACCIDENT, WAS AT OR NEAR THE POINT OF FRACTURE DUE TO THE MASSIVE LOSS OF CROSS SECTIONAL MATERIAL FROM THE FREQUENT IMPACTS (ON SUSPENSION COMPRESSION) BY THE MUCH HARDER/STRONGER BOLT TIP. IN OTHER WORDS, THE BOLT TIP ACTED AS A LATHE, CUTTING INTO THE SUSPENSION CONTROL ARM WITH EACH SUSPENSION CYCLE. IN THE SHORT TERM, I STRONGLY RECOMMEND AN IMMEDIATE INSPECTION OF THE TESLA MODEL S FLEET, BEGINNING WITH MODEL S'S THAT HAVE HAD THEIR POWERTRAIN LOWERED AND REINSTALLED, TO SEE HOW MANY OTHER MODEL S'S HAVE THIS IMPENDING CATASTROPHIC DEFECT. WHILE IT COULD HAPPEN, I WOULD BE HIGHLY SURPRISED IF THIS VIN WAS THE ONE AND ONLY CASE OF THIS BOLT BEING INSTALLED BACKWARDS. IN THE LONGER TERM, I RECOMMEND THIS BOLT BE REDESIGNED SO AS TO PREVENT INCORRECT INSTALLATION. PLEASE FEEL FREE TO CONTACT ME FOR ADDITIONAL INFORMATION AND FOR THE PHOTOGRAPHS. *TR

NHTSA ODI 10679347