What 592 owners told NHTSA about the 2019 Tesla Model 3 Bev

Heard rattling in the front of the car over a period of weeks. Finally checked and saw a bolt that secures the front wheel hinge to the body frame was very loose. Then I tried turning the wheel (while stationary) to test the front steering. After a few times, the bolt came completely loose and hanging, as in one of the pictures included. After the bolt came completely loose and hanging, the affected wheel is completely unaligned. Since the bolt is hanging, I simply removed it, as shown in one of the attached pictures.

NHTSA ODI 11576393

Both the front left and right lateral linkages have failed after 4 years of normal use. This is similar to an issue experienced in other Model 3 vehicles that were recalled. This vehicle is not covered by that recall but appears to have the same build quality issues. These links should not fail at such an early vehicle age. Replaced Left Front Lower Lateral Link. Replaced Right Front Lower Lateral Link.

NHTSA ODI 11573399

The upper control arms on this vehicle are a known chronic issue where the ball joints fail anywhere from 15,000 miles and up. Tesla is charging for this replacement if vehicle has more than 50,000 miles

NHTSA ODI 11572314

When driving the car and turning the wheel there was a creaking noise at low speeds. Upon inspection at the service center the issue was diagnosed to be suspension part issues. The compliance link assemblies, lower lateral links, and control arms require replacement. This issue could have resulted in the car wheels breaking off while driving, causing a safety issue for myself and others.

NHTSA ODI 11566247

Upper control arms and linkage on left and right needed to be replaced. Tesla charging $600 labor.

NHTSA ODI 11564766

The front upper control arms on the vehicle failed at around 50,000 miles. The control arms failed with the same symptoms described in Tesla's service bulletin [XXX] ). However, despite the service bulletin stating that the correction was to reseal the area around the ball joints, Tesla's service team told me that they no longer do that because they found out that the problem would reappear if they only reseal them. That they instead replace the front upper control arms with a newer version. They billed me $181.44 for that work despite having a service bulletin for the issue and despite it being a widespread issue with the early failure of those control arms. I was lucky that I had this issue addressed when it only made noise and did not wait for the suspension component to structurally fail, which would have resulted in a crash. I have the invoice and the written communication between myself and Tesla. However, when submitting this incident form on NHTSA's website, the Upload Files section wasn't working in Chrome or Firefox on Windows. Clicking the "Upload Files" button on this web form just made the button disappear and nothing else happened. If it is helpful, I'd be happy to share the invoice and written communication between myself and Tesla with NHTSA. Please let me know if that's needed. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11564327

I had to replace the Front Upper Control Arm Assemblies (Left and Right). As part of this (I believe) I also had to replace Lower Lateral Links (Left and Right) and the Front Lower Compliance Links (Left and Right). My car had 53,536 miles on it at the time (so just outside the warranty). The total cost was $1,259.63.

NHTSA ODI 11562593

The contact owned a 2019 Tesla Model 3. The contact stated that while driving at various speeds, there was a squeaking sound coming from the front end of the vehicle. The vehicle was driven to the local dealer who diagnosed that the front suspension system was faulty and needed to be replaced. The front suspension system was replaced, and the vehicle was repaired. The manufacturer was notified of the failure. The VIN was not available. The failure mileage was 93,000.

NHTSA ODI 11562367

The contact owns a 2019 Tesla Model 3. The contact stated that while turning the steering wheel to the left or the right, there was an abnormal creaking sound. The failure occurred at various speeds and occurred intermittently. The vehicle was taken to the dealer who diagnosed and determined that the creaking sound was coming from the front upper control arm while turning the vehicle and the front lower control arm while in reverse. The dealer also diagnosed that the latter link was torn. The contact was informed that the control arms and suspension nuts and bolts needed to be replaced. The vehicle had not been repaired. The manufacturer was not made aware of the failure. The failure mileage was 49,000.

NHTSA ODI 11560267

Suspension lateral links attached to subframe became loose causing the lateral links to separate from the sub-frame. Wheel alignment shifted causing instability, which adversely impacted vehicle controllability and nearly caused a collision while driving. Problem was inspected, reproduced, and confirmed by the dealer/manufacturer/service center. Before the failure occurred, the primary symptoms were abnormal noises from steering/suspension area. Service center attempted to address these noises by inspecting and retightening the bolts, but unfortunately, this action did not resolve the issues and, eventually lead to a failure of the suspension system. It should be noted that parking brake functions and vehicle hold feature may have been affected by this failure. This incident may be associated with with the following recalls, NHTSA Recall: 23V-235 or Manufacturer Recall: SB-23-31-001. However, my VIN does not appear to be included.

NHTSA ODI 11553170

Issue with control arm and compliance links. Poor design causes corrosion problem.

NHTSA ODI 11548645

I previously had asked Tesla to check my front suspension as I was noticing a unusual sound which they did however the technician assessment was that all was fine. Today, just 4 months out of warranty (but still under the 50k), the front control arm just fell off while I was driving. This resulted in the control arm to brake as well as my front fender (it hit the tire in motion). To my disbelief there was nothing put in place to keep that control arm up, if I were driving on the freeway it would have resulted in a catastrophic accident. I’m emailing you to see if there is anything that can be done to hold Tesla accountable for this major flaw. Online forums have plenty of other tesla drivers with similar issue as well as an official recall which unfortunately my vin did not fall under. Please advice on how to proceed. Thank you.

NHTSA ODI 11540640

Loud squeaking noise inside cabin while driving started immediately after warranty expires and software update. Steering shakes with bumps. Almost felt like something is falling apart. Tesla service said known problem and since out of warranty customer will be charged. Wonder why all problems started immediately after warranty expires. Pls investigate if this part ( control arms and suspension) cause any safety issues. Also, software updates should be investigated as well.

NHTSA ODI 11536211

The contact owns a 2019 Tesla Model 3. The contact stated that while driving at an undisclosed speed, the vehicle made an abnormally loud sound. No warning light was illuminated. The vehicle was taken to an independent mechanic, who diagnosed that the front suspension lateral link was fractured and needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The contact related the failure to NHTSA Campaign Number: 23V235000 (Suspension)however, the VIN was not included in the recall. The failure mileage was approximately 56,000.

NHTSA ODI 11532354

Left and right lateral links were blown. Increases the chance of a vehicle crash. Tesla has identified the issue in my vehicle and replaced both parts. There were no symptoms, the technician found it by inspecting the suspension due to an unrelated noise reported by me, the customer. There have been multiple recalls in the past for the Model 3 and Model Y manufactured in 2018 and 2019. Tesla has not issued any recalls for my vehicle. Now that my vehicle is off warranty, I was charged $803.50 plus taxes to replace both parts that should have been part of a larger recall. I suspect this is a recurring issue that Tesla is not addressing. The chances of having a similar issue on one side is already low. In this case, it is on both sides, which reinforces my suspicion.

NHTSA ODI 11528233

At just 10 days over 4 years of ownership, which is out of warranty, and at about 44,360 miles, I noticed noise when going over small bumps, moving from stop to go and while turning the steering wheel. It appears that the upper control arm, a recall on about 3000 Tesla Model 3 and Y, was the culprit. I contacted the service center and right away, over the Tesla Mobile App, the knew it was the control arm going bad. They said it was safe to drive, however, it is a bit scary to hear the squeaking and noises when driving and turning the steering wheel, especially at highway speeds. The problem was fixed by Tesla's service center, however, because I was 10 days or so out of my 4 year/50,000 miles warranty, I was charged about $190 for the repair. I feel that since this is a know issue and has happened to many other non-recalled vehicles by Tesla, this would/should be a know defect and safety concern that should have been repaired under warranty.

NHTSA ODI 11518766

I was driving using beta full self driving feature, and the vehicle was involved in a collision

NHTSA ODI 11509538

The front control arm fails just 58k mile mark this known issue on car. Multiple time brought to there attention no action was taken

NHTSA ODI 11508671

Front upper control arm is failing, making an awful noise and can be felt grinding inside the car while driving. Reported to Tesla service and they denied the repair. It is a known issue, they need to recall all effected vehicles for repair.

NHTSA ODI 11487396

Squeaking while turning left, right, and under load while braking in a straight line. Problem is upper and lower control arms. Also at time is sound like metal grinding in a circular fashion like a break pad on a rotor, or like an inner bearing going out.

NHTSA ODI 11487249

Broken control arms

NHTSA ODI 11485027

Squeaking suspension not allowing for a safe drive.

NHTSA ODI 11471464

You have many reports of Tesla Model 3 ball joint failures. The ball joints are failing due to lack of lubrication. If an owner complains enough Tesla will squirt some lube in and reseal with silicon goop. Owners are even DIYing with WD40. Here is a Tesla in the junkyard with upperball-joint popped apart and all other ball-joints busted. https://www.iaai.com/VehicleDetail/33393366~US Just wondering when you might get around to demanding a recall. Thanks Your friend Keef. Say Hello to Elon for me.

NHTSA ODI 11461981

The left front lower control arm came loose while I was getting out of my garage. The vehicle immediately became undrivable.

NHTSA ODI 11443958

squeaky sounds and shaking steering control due to the front 2 wheels upper control arm ball joints lost the lubrication. extremely laud squeaky sounds, the squeaky sounds is similar to car that about to fall apart in movies. resulting the model 3 driver has to be on high alert all time, scared if the wheels will fall apart or the steering will be out of control or difficult to control.

NHTSA ODI 11421183