What 982 owners told NHTSA about the 2018 Tesla Model 3 Bev

The front right lower control arm, sub frame, and bolt(s) failed causing unsafe driving conditions while myself and my kids were in the car. There is a recall on this part for many of the exact same year, make, and model as my car: NHTSA campaign ID: 23V235000. Tesla recall SB-23-31-001 (info pulled from NTSB site). My VIN wasn’t on the recall, but there is clearly an issue, so I was forced to pay for this. Please add my VIN so I can be reimbursed and also get the other side repaired for safety reasons.

NHTSA ODI 11577771

Front control arm and ball joints have been replaced twice for the same issue and I have looked into a bunch of message board groups and it's a common issue. Ball joints and control arm wear and rust abnormally and unusually fast. It happens about every 2 to 2.5 years.

NHTSA ODI 11577591

Full service history is detailed below. Since purchasing the Model 3 in April 2018, we have had three different instances of issues with control arms/suspension system. The most recent instance occurring this week (February 12, 2024) required the whole suspension system to be replaced with only 63,900 miles on the vehicle. The suspension system should not need replacing on a vehicle with only 63,900 miles on it. We have now had to pay Tesla $1,357.57 to continuously fix the issue with the suspension system on a car that is not even 6 years old with less than 64,000 miles on it. During an interaction with a Tesla technician for the second instance noted below, we were told that Tesla undersized the control arm leading to failures. He commented that they replace control arms on Model 3s on nearly a daily basis. This is clear negligence by Tesla and we would urge the NTSB to take immediate action. I know we are not the only Tesla Model 3 owners that have experienced control arm/suspension issues. Car Purchase Date: 4/7/2018, ~25 miles on vehicle Service Visit 1 on 7-23-2021 Odometer 42,790 Cause for visit: Creaking noise when turning or going over bumps Items replaced: 1) Front Upper Control Arm Left Parts = $0 (under warranty) Labor = $0 (under warranty) Service Visit 2 on 8-25-2022 Odometer 51,321 Cause for visit: Creaking noise when turning or going over bumps Note: Was told by service technician that Tesla undersized the control arm leading to failures. Commented that they replace control arms on Model 3's on nearly a daily basis. Items replaced: 1) Front Upper Control Arm Right Parts = $92.48 Labor = $0 Service Visit 3 on 2-12-2024 Odometer 63,898 Cause for visit: Car violently shudders when turning and felt like the front end side was going to collapse one time on a turn Items Replaced 1) 2x Lower Lateral Link Front - 2) 2x Lower Compliance Link - 3) Front Upper Control Arm Left Parts = $1019.99 Labor = $245.10

NHTSA ODI 11571717

Clunk and popping sound while driving, especially while turning the wheel or going over bumps in road. Maneuverability and control of vehicle felt impacted which could have resulted in an accident, damage to property, and injury and/or death of people. The issue was reproduced at the vehicle's Service Center and identified as a lose bolt that connects the front suspension lateral links to the subframe. This issue sounds very similar to a previous recall for the same make, model, and year of this vehicle, but the VIN for this particular vehicle was not included in that recall.

NHTSA ODI 11570900

This seems to be related to NHTSA Campaign Number: 23V235000. My front right hand lateral link bolt managed to back itself out and broke off the nut that contains the bolt. This is confirmed by Tesla service center in Burbank. This is a HUGE safety risk as the front end was not properly fastened and at highway speeds could have caused an accident risking injury and death. The only warning of the issue was a knock sound being heard when the car is turned fully at slower speeds. There was also a slight rattle heard while driving over uneven roads. The result was an out of pocket charge of $3000+ to the car owner. The car was never included in the original recall or the subsequent expansion of the recall. Clearly the issue is more wide spread and should be fixed by Tesla

NHTSA ODI 11568634

When seated in my car, I turned the steering wheel and I heard a clunk noise by the driver side. After trying to turn it back, my car dropped and I checked outside and it looks like something related to the axle or arms caused the issue. My axle seems to have separated and fell off and a bolt came off. This is a safety issue and I could’ve died if I was driving at higher speeds like on a highway.

NHTSA ODI 11567884

This vehicle has had steering squeaks for a really long time. I've had ball joints sealed, control arms replaced and now lateral links replaced for damaged bushings. This has cost me a significant amount of money and the bushings show tears that could have resulted in loss of control.

NHTSA ODI 11567235

At just over 50,000 miles, my Model 3 experienced a failure of its upper control arm on the drivers front wheel; the suspension was exhibiting loud creaking noises over bumps and road imperfections. While Tesla refers to this issue as "noise, vibration and harshness" and has previously applied a service bulletin to my vehicle where sealant was applied to prevent water ingress into the joint, continued driving on a failing component as critical as the suspension could cause an accident. Furthermore, they consider the repair something the customer has to pay for. My vehicle is currently sitting at Tesla service with no feedback as to the final cost of repair or even when they will complete the repair.

NHTSA ODI 11567041

Front suspension components need to be replaced due to loud creaking noise, vehicle is out of warranty and has only 42687 miles. There are several bulletins on related suspension issues, [XXX] Testa did replace the controls arms in this car on 09/09/2021 but it seems like the same defective parts were used. They replaced defective parts under warranty with the same type of defective parts but are refusing to warranty the repair since their parts only have a 1 year warranty. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11563535

Front suspension components needed to be replaced, vehicle was out of warranty and had only 43000 miles. These parts should last for much longer the 4 years and 43000 miles. No incident, but car squeaked at all speeds. Repair cost was $1600

NHTSA ODI 11562732

Tesla replaced the upper control arm assembly in February 2021 after I complained that there was a squeaking noise when moving the steering wheel. My car and components are available for inspection. I was concerned that the front suspension would break leading to an accident. Tesla inspected and confirmed the issue. No warnings or message were displayed by the car.

NHTSA ODI 11562503

At only 30,000 miles, the car began exhibiting terrible creaking sounds during colder temperatures whenever the suspension was active. Upon inspection, a Tesla technician claimed the ball joints on the upper control arms were “worn” and bushings on the lateral links were “torn”. Looking online, it’s clear this was due to defensive design/manufacture, as it’s happened to numerous vehicles. It appears that Canada and Europe have already forced Tesla to address these issues.

NHTSA ODI 11562656

Front upper control arm ball joints squeaking noise. Turning the steering wheel produces loud squeaking noise. The ball joints seem susceptible to outside elements (ie water from raining) and lose internal grease and dried up creating frictions. 2018 Tesla Model 3 Long Range

NHTSA ODI 11562379

After taking in my Tesla Model 3 for a loud creaking noise coming from the front right suspension, the Tesla service specialist said the suspension control arms are cracked and the car is dangerous to drive. I asked how this is possible. The Tesla specialist said the suspension is made of aluminum and cannot support the weight of the car. He said this is a known issue. However I was told I need to pay $2,300 for the repair because the car is out of warranty by 1 year. Since my car has under 29,000 miles, and this is a known flaw that is not the fault of the driver, I feel Tesla should pay for the repair. At this point I cannot afford to pay for the full repair (I paid for only the creaking fix which cost $400), so I am forced to ground my car until I earn enough money to pay for the repair. In my view this is wrong, and ask for NHTSA to investigate why such a dangerous flaw is allowed to persist, with consumers forced to pay for its repair - even on a car with less than 30,000 miles. Thank you for your attention. PS, this webpage does not allow me to load any files (I am using Safari). I would like to upload the detailed Tesla service estimate.

NHTSA ODI 11562413

Same exact issue as NHTSA ID: 23V235000 but for some reason my VIN is not part of the recall. Had to get it repaired by Tesla and paid out of pocket.

NHTSA ODI 11562031

A bolt in the control arms of my Model 3 broke. I took it in for repair. They blamed me for hitting the bottom of the car. They changed both upper and lower control arms and charged me about $500 for it. This is a major safety problem that Tesla doesn’t accept the blame for, even though I have seen many complaints online about this issue. They should recall all the affected models and fix it before it causes dangerous situations on the road.

NHTSA ODI 11562152

The front suspension lateral link fasteners on the driver side wheel came loose and fell off the car in my driveway when I was backing up the car. There is an active recall for this issue - 23V235000, but my VIN wasn't included in that recall.

NHTSA ODI 11557934

Driver side compliance link bushing and lateral link bushing were both torn and required replacement of entire lateral and compliance links. Major suspension components failing when the vehicle has only 27k miles is unacceptable and unsafe, potentially effecting drivability. Obviously poor quality parts were used during manufacturing and replacements should be covered by recall or goodwill regardless of whether the vehicle is under warranty or not. I found several online articles describing this problem and it is a known issue. [XXX] [XXX] [XXX] The Tesla service manager admitted the problem, stating he sees a lot of control arm and bushing problems. Yet Tesla refused to stand behind their product, and charged nearly $1500 for the repairs. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11557793

First Occurrence (5 Oct 2023): On 5 Oct 2023, as I was backing my 2018 Tesla Model 3 into a parking spot, I heard a loud metallic sound as I turned the wheels. I stopped the car to investigate and found a large bolt (about four inches long) under the front end of the car. Further inspection revealed that a similar bolt was partially backed out of the steering linkage. I also noticed the left front wheel was no longer aligned with the right front wheel. I determined the car was not drivable and I had it flat-bedded to the nearest Tesla Service Center. The service center diagnosed that the bolt had fallen out of the left lateral link and the other bolt had partially backed out. Inspection of the bolt that was recovered under the car showed no sign of wear and tear with the threads being in good condition. After the repair was completed, I asked for this bolt back for the record, but the Service Center said they no longer had the bolt. Before the repair was performed, I asked the Tesla service manager to try to determine why this bolt may have fallen out and the other bolt partially backing out. He inspected the car as well as investigating past Tesla service history and there was no evidence of damage or a repair that would have caused this issue. Second Occurrence (20 Oct 2023): On 20 Oct 2023, just 9 days after the repaired car was returned, I heard the same loud mechanical sound and scrapping noises while parking the car. I looked under the car and found the bolts on the right lateral link had started to back out. I returned the car to the service center on 21 Oct 2023 for a second repair. I voiced concern that this was a continued safety issue as bolts on critical steering and alignment components should not just back out. Fortunately, the bolts fell or backed out in a parking lot and not while travelling at 70 mph ---- potentially resulting in a serious accident and injury. NHTSA Recall 23V-235 should be expanded to more VINs.

NHTSA ODI 11557065

Front left tire control arm completely separated from suspension with no obvious warning. Fortunately happened while backing out of driveway otherwise could have been catastrophic on street/freeway.

NHTSA ODI 11554716

My car has has very loud creaking sounds coming from stabilizer links and upper control arms. This is a known defect and there are already service bulletins about this. Those bulletins are: SB1831005R1, SB-20-31-006 R3, SB-18-31-005 Unfortunately, when I took my vehicle into be repaired, they said that my VIN isn't covered by this recall... Yet, I am having the same issue. Tesla charged me $2,186.46 to fix it when it should have been free.

NHTSA ODI 11554568

While traveling approximately 20mph, I heard a loud noise from the front of the vehicle. It sounded like I hit a road hazard, but the road was clear. I inspected the front of the vehicle and there was no visible damage. However, from then on, the vehicle would make a loud clunking noise whenever I made a turn, no warning lamps or messages. I was able to drive to a Tesla Service Center and they diagnosed it as a failure of the Front Lower Lateral Link. There have been recalls associated with the lower lateral link (SB-21-31-001) for 2018-2019 Model 3 vehicles, but my VIN was not part of that recall. It should have been part of recall.

NHTSA ODI 11548525

The front suspension started making a lot of loud noises, the service center acknowledged that it's a control arm issue potentially however my VIN is not listed in a recall that was conducted for this manufacturer and they're doing more recalls on it but the manufacturer says that I have to pay for the repair despite it being a safety issue for the control arm not being tightened to the frame and suspension and potentially dislodge.

NHTSA ODI 11546794

I noticed noise coming from the front driver's side wheel especially when turning. Upon inspection, I found that a nut was missing from the front suspension lateral link that fastens the link to the sub-frame. Also, the 2nd bolt fastening the link was very loose. This is exactly what happened as noted in the NHTSA Part 573 Safety Recall Report - 23V-235. Tesla service says that "there are no open campaigns for your vehicle for nuts missing". Well there needs to be as this is very dangerous.

NHTSA ODI 11544889

The contact owns a 2018 Tesla Model 3. The contact stated while driving 25 MPH, there was an abnormal sound coming from the vehicle. There was no warning light illuminated. The vehicle was taken to the dealer and the contact was informed that the front upper control arm, and the shifter cable needed to be replaced. The vehicle was repaired. The manufacturer was not contacted. The failure mileage was 39,000.

NHTSA ODI 11540617