What 604 owners told NHTSA about the 2016 Tesla Model S 75d

While driving, left front lower fore link broke. Front wheel became lose in the fender well. Smashing the wheel front and back in the well, whilst pulling the car very hard to the left. Front link completely broken. Inspection shows, two rear links cracked and ready to break . Telsa knows about this in Safety Bulletin SB-17-31-001 . They did not notify us. And additionally refuse to fix it unless we pay over $10,000 in repairs. I purchased this car brand new. Has never been wrecked, well serviced and well maintained.

NHTSA ODI 11498581

Tesla vehicles suffer excessive “toe-in” wear on all tires. Tesla claims it is a function of the vehicle being heavy and that it is “normal” Tires have to be replaced every 12-24 months as a result of the inner portion showing cord, wire, and losing air. The tread on the rest of the tires appears to have 1/8 to 1/4 inch of usable tread however all tires have to be replace as a result of the toe in. Vehicle was repeatedly aligned by Tesla but that did not alleviate the issue. Presents a real danger as the portion of the tire dangerously worn down is on the most inner side of the tire. Not easily visible.

NHTSA ODI 11497384

While driving with Auto Pilot engaged on the highway, traffic slowed and AP applied the brakes at a light to moderate level. I immediately heard a loud squeal come from the front passenger wheel area that stopped when braking stopped. No warning lights or messages showed but I could tell I had reduced steering response after disengaging AP. I was able to get off the highway and navigate to a nearby service center, where they told me that a ball joint had sheared off. The squeal was a result of the tire contacting the wheel well. The service estimate called for replacement of right and left fore link and aft link assemblies of the front suspension. A web search revealed that Tesla was aware that "Some Model S and Model X vehicles may have been manufactured with front suspension fore links that may not meet Tesla strength specifications," per service bulletin SB-17-31-001.

NHTSA ODI 11497330

Drivers side suspension fore-link failed while driving. There was no warning, simply a loud "clunk" sound. I was able to limp the vehicle home, and then to the service center several days later. The fore-link completely failed while driving to the service center, causing the wheel to interfere with the inner fender, requiring us to stop. The dealer replaced the fore-link, however, we were required to pay for the replacement. There is currently a TSB for this issue, however, Tesla indicated that our VIN wasn't included, despite being within the dates of manufacture listed on the TSB. https://static.nhtsa.gov/odi/tsbs/2017/MC-10110741-9999.pdf Do I have any recourse to get Tesla to reimburse me for the cost of replacing my fore links? Thank you!

NHTSA ODI 11493833

When backing up in a level parking lot, heard a loud crunch (something like rolling over a large plastic beverage bottle). Subsequently, heard frequent "scraping" sounds when turning. Took to Tesla for service - technician diagnosed "broken lower driver side forelink" - replaced (at cost of $701.36 to me). Technician reported "inspected passenger side forelink and did not need to be replaced." Tesla did NOT give me the replaced (broken) part.

NHTSA ODI 11493626

While backing out in my driveway, which has a gentle slope, the front suspension link broke and the front part of the chassis/fender scraped against the driveway surface making scraping sounds of friction and damage underneath the front fender. It is certainly a safety issue and I am glad I was still near home and not on the road, especially highway. I could see a broken metal part on the driveway which I showed the service personnel. The car has barely 45000 miles on it. It is used solely for city driving on mostly flat roads (including Cupertino to Palo Alto office commute). I bought the car in August 2018 from a certified used car dealer with 18000 miles on it. The car was not driven that much during the pandemic closure for about 1.5 years. There was never a service reminder sent by Tesla. So this is completely unwarranted that a critical part like suspension link will randomly break apart! I see that this is an issue known to NHTSA (https://www.reuters.com/article/tesla-safety-investigation-idINKBN2871ES), but I did not receive any recall notice from Tesla. Therefore the service station is charging me full money for the broken fore link as well as the yet unbroken fore link on the other side, and suggesting that I replace the aft links too. This seems totally unfair that the customer has to pay large sum for a mechanical failure known to Tesla.

NHTSA ODI 11486962

The contact owns a 2016 Tesla Model S. The contact stated while driving approximately 15 MPH, the brake pedal was depressed to avoid hitting an animal and the suspension detached from the vehicle as wheel well the front driver’s side wheel was loosened and the wheel rail liner was fractured. The contact stated that no warning light was illuminated. The contact stated that he was able to drive the vehicle back to the residence. The local Tesla Service Center was contacted; however, the cause of the failure was not yet determined. The dealer informed the contact that the suspension needed to be replaced but the part was not available. The vehicle was not repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 44,000.

NHTSA ODI 11484458

The contact owns a 2017 Tesla Model S. The contact stated that while driving at an unknown speed, he heard an abnormally loud sound come from the driver’s side wheel. The contact pulled over and inspected the wheel but did not see an issue. The contact stated that he continued driving and while driving approximately 35 MPH, the driver’s side wheel detached and went into the wheel well. The vehicle then began to steer slowly to the left independently and the contact was able to get the vehicle into a parking lot. The contact stated there was no warning light illuminated. The contact stated that the vehicle was towed to his place of employment. The local Tesla dealer was contacted however, the cause of the failure not yet determined. The dealer informed the contact that the driver’s side control arm needed to be replaced but the part was not available. The vehicle was towed to the dealer where the contact was informed that the failure was not related to the control arm, but that the wheel well and the front fascia lower valence needed to be replaced. The vehicle was repaired. The manufacturer was not made aware of the failure. The failure mileage was 140,466.

NHTSA ODI 11484479

I purchased a used 2016 Tesla Model S in September 2021, with 58,961 miles. Within a month, a strange scraping sound can be heard as I was backing out of my driveway, it was the metal piece that was connected to the wheel. Somehow it had broken off and was bent in a position where it was grinding my brake pads down to unsafe levels. Telsa said it was caused by making a 'sharp turn' and is not covered under warranty. The work to fix costed $1450.03 to replace brake pads and wheel that was cracked. But didn't disclose in the invoice what was causing the scraping sound. They claimed that when they drove the vehicle they could not hear any scraping sound. Based on Tesla's TSB report, this is a known defect and Tesla should have repaired it without charging me. But they would rather have me believe that I was a terrible driver.

NHTSA ODI 11483850

My car has only 50,000 miles but suspension is making noise. Tesla dealer is saying they need to replace the Links - Front Suspension - Lower - Aft -LH/RH. Tesla is charging me $1,828.87 to replace these links. I see in the internet that lot of 2016/2017 made cars has this defect. I strongly believe this is manufacturing defect and Tesla is responsible for fixing this issue for all effected customers. I appreciate if you can investigate into this issue.

NHTSA ODI 11482467

Lh suspension fore link broke causing tire to rub inner wheel well while driving at around 30mph resulting in damage to tire and wheel well liner .... car was not able to be driven ..... Tesla service center was not willing to repair under warranty or good will even though they issued a tsb regarding certain 2016 model s cars having suspension parts that were not up to Tesla quality standards and could result in failure

NHTSA ODI 11482143

I could hear a noise in the front suspension while driving. Upon returning home the front driver side suspension collapsed while I was parking the car. The front suspension link broke and the wheel was rubbing against the arch liner. I was lucky that the failure occurred at very low speed but the damage could have been significant if it had happened just a few minutes earlier, while driving.

NHTSA ODI 11479351

Drivers side fore links broke under warranty. Per Tesla Service bulletin SB-17-31-001 filed February 17, 2017 for automobiles manufactured between January 19 and May 25, 2016, if one of the fore links break both should be replaced. Per the attached invoice and scree shots, Teslas service center in Raleigh is refusing to follow the bulletin citing that the vehicles ein is not eligible but showing no proof. Attached is an email from that shows the car finished manufacturing on May 8,2016. I'm requesting Tesla to follow their service bulletin and include replacing the passenger side fore link as part of their warranty service.

NHTSA ODI 11479219

Suspension Component: RH Front Aft Control Link - I will provide the damaged/exploded part via FEDEX to your office. Event happened while backing out of garage, was under 5miles speed and hence nobody was injured or put at risk. Could have gone worst if this would have happened at higher speed/highway. There was no prior warning, corrosion and/or indication alerting of wear & tear on the part that was broken. This car has very low mileage (44k miles over 6 yrs) for some major component to fail like this without notice.

NHTSA ODI 11475423

I was traveling on HWY 98 in Florida, headed home to Austin, TX from vacationing. I was with my wife and three young children. I stopped at a stop light, and when I went to reaccelerate, the car lurched. I pulled over and discovered I could barely turn and the suspension was making a terrible sound. I was able to maneuver into a parking lot and determined that my front driver's side fore link had cracked and was no longer holding. There is an existing Service Bulletin (SB-17-31-006) that should have covered this. My car is in warranty, and I have had it serviced before the accident, but after the publishing of the SB and Tesla never notified me that the links should be replaced. This was a tremendous hassle, and posed a very serious safety issue, because the broken link can protrude through the wheel well can cause the wheel to lock up.

NHTSA ODI 11471406

Suspension control arm failure on front left and right. It happened twice on two separate occasions while driving. Before failure it was making a creaking sound. It failed while driving on both occasions. The first failure happened pulling out of the driveway. The second failure happened driving down the street and it certainly put myself and others on the road at risk. Speed was fairly slow when it failed ~20 mph. Nevertheless, it was a busy street with cars going fast around us. The upper control arm broke on both occasions. The car is driven as one would expect. Around town and regular highway driving. No other accidents, off-roading, no notable potholes, etc. Unfortunately, even after recent repairs it is again making the same sounds that it made right before the previous failures. Tesla is refusing to fix the defects. This is likely the same issue as the recall in China.

NHTSA ODI 11468405

The Driverside Front suspension fore links completely failed and broke off, and separated and it made the Tire shift towards the the wheel arch liner and rub against it which damaged the tire and the wheel arch liner. And it caused the Front suspension LINK bushing to become damaged as well when the FRONT SUSPENSION FORE LINK broke ( the metal completely broke in half & became separated from each other ) because the two links are connected together to the front suspension arm wishbone on top when I was driving down a residential street going 20 mph, there was a small dip in the road so I slowed down to about 5 mph and after the dip I noticed this loud sound coming from my front tire & wheel. I think it was already cracked and the dip made it come off. Because that small dip could not of had the torque & power to do that to the metal on the front suspension Fore link. I own 2016 TESLA MODEL S 75. I researched and Many teslas are having the same problem!! Tesla even put out a service bulletin SB-17-31-001 stating “Some Model S and Model X vehicles may have been manufactured with front suspension fore links that may not meet Tesla strength specifications. In the event of link failure, the driver can still maintain control of the vehicle but the tire may contact the wheel arch liner.“-years affected 2016 OMG Which exactly happened to my 2016 TESLA MODEL S 75!! Now I found there’s a class action lawsuit vs Tesla and NHTSA INVESTIGATION about the same exact matter! My car is not driveable, I called Tesla roadside to get it towed to Tesla service center, they told me I would have to pay for the tow!! I made a service appt but it’s not until another 7 days! I’m waiting to find out if Tesla will cover the cost to fix it??

NHTSA ODI 11467085

Driver side fore link failure, driver side suspension collapsed on the tire. The car came to an immediate stop. The car did go up in the air for some time before stopping. Since the driver side fore link failed, Tesla said that they have to change both the fore links.

NHTSA ODI 11456643

Left suspension front fore link broken, damaged left front tire and wasn't driable.

NHTSA ODI 11449355

The contact owns a 2016 Tesla Model S. The contact stated while driving approximately 10 MPH, he heard a popping sound coming from the vehicle. The contact exited the vehicle and inspected the vehicle but found no failure. There was no warning light illuminated. The contact continued driving however, at 5 MPH he heard another popping sound. The contact called a local towing company to have the vehicle towed to the dealer. While attempting to place the vehicle on the flatbed, the contact was informed that a large metallic part had fractured and detached from the vehicle. The dealer’s diagnostic result was that the driver’s side front lower fore link collar had broken off the vehicle. The vehicle was repaired out of pocket. The mechanic was not made aware of the failure. The approximate failure mileage was 57,000.

NHTSA ODI 11447315

Car was being pulled out of parking spot and front suspension failed. TESLA rode side service took car to TESLA dealer. TESLA said car was too heavy for parts and now the knuckles and the fore links for the front suspension need to be replaced. The car had a full alignment in February and everything was good. They said they were aware of a problem others are concerned about bit they can't do anything at this point as there is no open recall in the United States.

NHTSA ODI 11445429

Front control arm separation.

NHTSA ODI 11441355

The right Front Lower Control Arm broke off. When I applied the break (abruptly) at the light ( driving speed ~35mph and the street was wet), the front right wheel was bouncing and making a weird noise. I managed to drive home and found out that the control arm has broken off. I did some research and realized that this is a common problem with Tesla vehicles. I am wondering if this is a recall issue. This is a safety issue and I think Tesla needs to recall and fix this problem.

NHTSA ODI 11439621

The contact owns a 2016 Tesla Model S. The contact stated that while driving approximately 30 - 35 MPH, a loud bang noise was heard, then the front passenger’s side tire kicked back and damaged the wheel. Upon inspection, the contact saw that the front passenger’s side control arm was fractured. The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 140,000.

NHTSA ODI 11439518

I was backing out my car from the garage at home and on the driveway my wife and I heard a weird sound. After checking we found a broken metal part on the driveway and a closer look, taking a picture, I could see that the suspension arm for the front passenger side wheel was broken, very much metal fatigue,

NHTSA ODI 11436810