What 434 owners told NHTSA about the 2020 Tesla Model 3 Bev

Suspension defects, control arm noise, vibration, .

NHTSA ODI 11750088

The contact owns a 2020 Tesla Model 3. The contact stated that while driving at an undisclosed speed, there was a clinking sound coming from the front of vehicle. No warning lights were illuminated. The contact stated that the dealer was contacted, and a repair was pending on the lower lateral link. The contact stated that the VIN was not included in NHTSA Campaign Number: 21V835000 (Suspension). The contact associated the failure with the recall. The manufacturer was not made aware of the failure. The failure mileage was approximately 40,000.

NHTSA ODI 11746313

This was not an incident. Instead I’d like to report it as a design flaw. I discovered low speed noise and got it fixed at Tesla service center. Upper control arms and lower control links have both been replaced at ~70k miles and the cost to repair was over $2k at Tesla service center in Feb 2026. Later in May 2026 Tesla published a service bulletin acknowledging this is a design flaw

NHTSA ODI 11743946

The contact owns a 2020 Tesla Model 3. The contact stated that while driving at various speeds, the vehicle made an abnormal clunking sound while turning the steering wheel. The messages "Traction Control Disabled", "Lane Departure Avoidance Feature Disabled", "Automatic Vehicle Hold Disabled" and "Stability Control Disabled" were displayed. The vehicle was taken to a dealer, where it was discovered that the lateral link was not attached to the control arm due to a defective bolt. The contact was informed that the subframe and the front passenger’s side lower control arm needed to be replaced. The contact related the failure to NHTSA Campaign Number: 21V835000 (Suspension); however, the VIN was not included in the recall. The vehicle remained with the dealer unrepaired. The failure mileage was 46,124.

NHTSA ODI 11734843

Sunday [XXX] downtown Sacramento, driving about 25 mph. Heard a loud bang—bolt sheared off front subframe. Steering felt lagging upon making a right turn vehicle proceeded in a very wide turn, pulled into parking lot. Wheel locked right as I exited [XXX] parking spot; steering went slack, brakes scraped rotor. Two witnesses saw hardware hit pavement. AAA tech removed tire: lower control arm bolt missing, no Loctite, subframe raw. Second bolt loose—single point of failure. Tesla missed this on six different service visits and during their one-twenty inspection before delivery. Recall 21V835 should’ve flagged it but service personnel assured me all clear on every visit . Vehicle towed to Tesla service center at 1104 Tinker rd, Rocklin, CA. Tesla shop manager Sal confirmed this failure as manufacturers defect, and poor assembly. Safety was seconds from total loss. Need probe. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11715438

The front suspension control arms on my 2020 Tesla Model 3 are squeaking and show premature wear. The noise occurs during normal driving and is accompanied by clunking, which concerns me about potential control arm failure and loss of vehicle control. My vehicle is only 40k miles and it’s a very common issue that Tesla gets to make money on. Kind of funny it happens to everyone right when the warranty ends. I am aware that this is a known issue affecting multiple Model 3 vehicles. Despite proper maintenance, the problem persists and may present a safety risk. I request that this be officially recorded as a safety complaint.

NHTSA ODI 11714618

Vehicle made thunking noise when driving over uneven surfaces such as bumpy roads, speed bumps, or railroad tracks. Diagnosis at Tesla service center showed front upper control arms assemblies (left and right), lower lateral link, and front lower compliance link (left and right) required replacement. Of note: upper control arm assemblies were previously replaced under warranty in November 2021 at 28000 miles. This short interval indicates defective suspension components leading to cascading failures putting driver safety at risk.

NHTSA ODI 11711819

My Tesla Model 3 is experiencing premature suspension failures involving the lower lateral links and stabilizer links. These components were already replaced once, and they are failing again in less than 30,000 miles. This is not normal wear for suspension parts on a modern vehicle. These failures cause clunking, instability, and looseness in the front end—conditions that affect the vehicle’s ability to track straight and maintain control, especially over uneven pavement or during emergency maneuvers. This isn’t an isolated case. There are extensive reports from other Tesla owners across multiple models (Model 3 and Model Y in particular) showing the same premature wear on these suspension links. Many owners have parts failing even earlier. Once the car is out of warranty, Tesla charges thousands of dollars to replace these components, despite clear indications that the suspension was under-engineered for the weight of the vehicle. Tesla knows this is a recurring issue but refuses to issue a recall or goodwill repairs. A repeated failure of critical suspension links in such low mileage suggests a defect. These parts should not be wearing out this fast, and the resulting instability poses a real safety risk. I’m requesting NHTSA investigate these premature failures.

NHTSA ODI 11703787

I am writing to formally report a critical safety incident involving my 2020 Tesla Model 3, where the bumper detached while driving through a puddle of water on Oct 9th, 2025. This occurred on a busy street, and fortunately, another driver alerted me just in time, averting a potentially serious accident. Following the incident, I arranged for my vehicle to be towed to a Tesla-authorized collision center and opened a claim with my insurance company. I have since learned that this issue is recognized internally by Tesla, as they have created a service incident regarding it, but have failed to communicate this to customers effectively. Tesla's lack of accountability is concerning. Despite repeated attempts to address this with their support and service teams, they have deflected responsibility and continue to downplay the seriousness of this matter, insisting I must rely on insurance to cover the costs. This situation raises significant safety concerns, not just for myself but for all Tesla Model 3 drivers. I urge NHTSA to take the following actions: 1. Investigate this safety issue regarding the bumper detachment on Tesla Model 3 vehicles. 2. Pressure Tesla to publicly acknowledge this known issue and take immediate corrective action to prevent future occurrences. 3. Ensure that affected customers are compensated for damages and repairs due to this defect. I appreciate your attention to this serious safety issue and look forward to seeing NHTSA hold Tesla accountable to protect all consumers and ensure vehicle safety. I have attached proof of diligent efforts on my part to get this resolved: - Claim number with Progressive - Communication with Tesla giving them proof of this issue - Earlier NHTSA bulletin acknowledging the issue and the Tesla internal service incident created for this issue. Thank you for your urgent attention to this matter.

NHTSA ODI 11692513

Front lower and upper control arms started generating noise around 100,000 miles. This was confirmed by an independent service center. So far, have spent $1400 on the lower control arms, only to find out that the noise is still there and the upper control arms need to be replaced as well.

NHTSA ODI 11680531

The front suspension is failing. I have already replaced the upper control arms. Now I need to replace the bushings on compliance and lateral linksare tearing. There have been recalls for this model and year, for this issue. My VIN, is not included in the recall. I was notified of the aditional needed repairs when I had the upper control arms replaced.

NHTSA ODI 11656828

I am experiencing persistent front suspension issues with my Tesla Model 3 Performance. The vehicle has been taken to a Tesla Service Center three times, yet the problem has not been resolved. The issue includes: Unusual noises (clunking, knocking, or creaking) from the front suspension. Instability or poor handling at various speeds. Repeated failures of suspension components despite repairs. Each time, Tesla service has attempted repairs, but the issue continues to persist, raising serious concerns about the safety and durability of the suspension system.The vehicle is currently at Tesla service center as of March 4th 2025 and they are working on the same problem for the 3rd time.

NHTSA ODI 11646474

THE FRONT CONTROL ARM IS DAMAGED, INTERESTINGLY ABOUT 6 MONTHS AFTER THE WARRANTY HAS EXPIRED. TESLA REPAIR TECH TELLS ME ITS SO COMMON THAT THEY DON'T CHARGE FOR THE REPAIR BUT DO CHARGE FOR THE PART. AS I SIT IN THE TESLA REPAIR CENTRE WAITING FOR IT TO BE FIXED, 3 OTHER PEOPLE WITH EXACTLY THE SAME PROBLEM JUST WALKED IN DESCRIBING EXACTLY THE SAME PROBLEM. I DON'T UNDERSTAND WHAT THIS PART DOES BUT GIVEN IT'S PART OF THE SUSPENSION, IT POSES A SAFETY RISK. THERE WERE NO WARNINGS EXCEPT FOR A VERY LOUD SQUEAKING NOISE EVERY TIME THE CAR TURNS OR ENCOUNTERS A BUMP

NHTSA ODI 11629018

Received several "Steering Assist Reduced" alerts when stopped in traffic last week, followed immediately by the failure of the power steering after each alert. Power steering resumed after a soft restart. Tried to make appointment at Tesla Service Center last Friday to get this addressed, but they said they had no appointments available and would not be able to diagnose my vehicle until today, August 12, 2024.. In the interim, the power steering went out again while on the freeway, forcing me to exit and restart the vehicle again. This is a clear danger to myself and my passengers. After receiving the results of the diagnosis today, they informed me that both the steering rack and harness would need to be replaced at the cost of nearly $5,000. The technician showed me some corrosion in one of the electrical connections where there had been water intrusion. I told him this was surprising since the car is relatively new and it would seem that Tesla would have sealed this connections to resist the relatively dry rainy seasons we experience here in Southern California.

NHTSA ODI 11608107

upper control arm is creaking, extremely common problem, we need to demand a recall

NHTSA ODI 11587314

I am writing to express my concern regarding the recurring issue with the control arms and sway bar in the 2020 Tesla Model 3. It has come to my attention that Tesla acknowledges this issue, which manifests as creaking sounds during various driving conditions such as climbing into the car, traveling at low speeds, and navigating over speed bumps or uneven terrain. What's particularly troubling is that when I brought my car into them Tesla acknowledged that they are aware of the prevalence of this issue across many of their vehicles, yet they continue to charge consumers for repairs, even if their vehicle is not included in the recalled VINs. This policy unfairly burdens consumers who experience the same issue but are denied coverage under the recall. I urge the NHTSA to investigate this matter thoroughly to ensure consumer protection and fairness in addressing safety concerns in Tesla vehicles. It's essential that manufacturers uphold their responsibility to rectify known issues without imposing undue financial burdens on consumers.

NHTSA ODI 11584266

My vehicle is 4 years old. 3 weeks after the expiration of my original warranty, the front suspension now squeaks loudly when driving at low speeds. This issue matches the known manufacturing defect described in Tesla’s 2021 service bulletin, “Reseal Front Upper Control Arm Ball Joints.” We never received this bulletin from Tesla, and we were never given the option of resealing the joints. As a consequence, the ball joints have now failed and both upper control arms must be replaced, at a cost to me of $330. I asked if Tesla can waive these repair costs due to the bulletin and widespread manufacturing defect, but Tesla declined, stating: “Your vehicle is not listed as an affected VIN for this bulletin. In order for a repair bulletin to be covered under the vehicle warranty the condition has to be reported within the warranty period. Once no longer under warranty, it is not covered.” Even though my VIN was not included, clearly it should have been since the ball joints have failed. Also, if this is a known car defect, why should it matter when the problem starts to appear in order for Tesla to take full responsibility and fix it? They are shifting costs to consumers for their own, known, widespread manufacturing defects. Additionally, if I had been informed about the bulletin in 2021, resealing the joints at that time would have been easier & far cheaper than replacing both arms now. It’s my understanding that Senators Markey (MA) and Blumenthal (CT) expressed concern that this defect could be a safety risk, and urged Tesla to issue a voluntary recall, which Tesla declined. I hope NHTSA will consider investigating this manufacturing defect further. Thank you very much for your time. Vehicle is available for inspection. Yes, an independent service center confirmed this suspension problem. A Tesla repair service center will inspect the components on [XXX]. No, there were no warning lamps, messages or symptoms prior to failure. The failure began on [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11582019

Car has 39,445 miles on it. Groaning noise started in front tires. Took it in for inspection and Tesla replaced the upper control arm and lower lateral link for both the front left and front right tires. I see that there was a recall for these parts in many Tesla 3, including my model year but my VIN didn’t qualify. Seems coincidental that I would have an issue with the same part that was recalled at only 40k miles but not under the recall.

NHTSA ODI 11568902

Driving the vehicle will start doing several noises in the front and back suspension. It’s very stressful to hear that kind of noise besides that people isn’t really sure it suspension going to fail at some point which potentially could be really dangerous. Tesla has recall this kind of issues outside the us but refuses to do a recall in the us where the have most of their cars risking the roads. added to that they should’ve included a spare tire kit on their cars.

NHTSA ODI 11568404

The contact owns a 2020 Tesla Model 3. The contact stated while driving approximately 40 MPH, the vehicle rolled over an uneven road surface and the contact heard an abnormal creaking and squeaking sound coming from the front driver’s side wheel well. The contact stated no warning light was illuminated. The contact stated that the failure was intermittent at first but had become a recurring failure at various speeds. The contact stated that the sound had become much louder. The contact had taken the vehicle to a dealer, where it was diagnosed and determined that the driver’s and passenger’s side front upper control arms and lower links needed to be replaced due the seals deteriorating and disintegrating. The vehicle had not been repaired. The manufacturer had been informed of the failure. The failure mileage was 59,135.

NHTSA ODI 11545448

my son-in-law went straight off country road and into a tree car burnt to ground was burnt to death date was [XXX] sheriff Spokane county investigating teal front suspension repaired 1 month before at local Tesla shop Spokane wa INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6

NHTSA ODI 11533202

The upper control arm on my vehicle creaks and it is a known issue amongst the Tesla model 3 owners. This creak can eventually wear to the point the ball joint will separate during driving. This is a safety issue that can cause an accident. Tesla denied the warranty repair due to some after market parts. This is not a valid reason to deny me warranty because this issue is prominent in all cars of this model and year regardless of aftermarket parts or not. Currently the issue is present at low speeds. Tesla applied a "patch" to keep water from getting into their poorly designed ball joint. Unfortunately by the time they got to this repair for my vehicle it was too late. And water had gotten in and caused the damage and now it is a safety concern.

NHTSA ODI 11455759

Driving home at 60mph when the right front wheel fell off the vehicle causing damages to the whole right side on the car.

NHTSA ODI 11419387

HERE IS A TESLA MODEL 3 IN THE JUNKYARD. HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39653751?TENANT=US&ROWNUMBER=19 ALL 3 BALL-JOINTS ON THE FRONT RH STEERING KNUCKLE HAVE POPPED APART. THIS IS HAPPENING SO FREQUENTLY ON TESLAS THAT IT IS OBVIOUS THEY ARE USING POOR QUALITY SUSPENSION AND STEERING COMPONENTS. THE OWNER OF THIS TESLA WAS LUCKY BECAUSE ONLY THE CAR WAS DAMAGED. THESE FAILURES ARE CERTAIN TO CAUSE DEATH AND INJURY IF NHTSA CONTINUES TO STAND BY AND DO NOTHING. THIS IS DISGRACEFUL. PLEASE TAKE IMMEDIATE ACTION. THANK YOU KEEF

NHTSA ODI 11407536

THIS IS A COMPLAINT ABOUT THE ISSUE OF POPPED BALL-JOINTS WHICH IS AFFECTING ALL MODELS OF TESLA CARS. HERE IS JUST ONE EXAMPLE OF A BALL-JOINT THAT HAS POPPED APART FOR NO GOOD REASON. HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39240789?TENANT=US&ROWNUMBER=3 IT IS EASY TO FIND OTHER EXAMPLES OF THIS SAME FAILURE IN OTHER TESLA AT THE JUNKYARD. I WILL ATTACH A FEW PHOTOGRAPHS TO SHOW YOU. THES BALL JOINTS ARE OF LOW QUALITY, UNDERSIZED, PRONE TO CREAKING AND GROANING DUE TO LACK OF GREASE WHICH CAUSES THE BALL TO WEAR DOWN AND POP OUT. THE TESLA FORUMS ARE FILLED WITH REPORTS ABOUT THIS. ELON MUSK HAS ADDRESSED THIS BY NERFING THE FORUMS. DEFINITELY A GENIUS. LINKS TO OTHER POPPED TESLAS.HERE: HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39311673?TENANT=US&ROWNUMBER=11 POPPED FRONT AND WHOMPY REAR HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39310125?TENANT=US&ROWNUMBER=15 POPPED HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39308954?TENANT=US&ROWNUMBER=22 POPPED HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39282369?TENANT=US&ROWNUMBER=24 POPPED HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39280909?TENANT=US&ROWNUMBER=30 POPPED HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39265721?TENANT=US&ROWNUMBER=33 POPPED AND THEN BURNED TO A CRISP HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39248729?TENANT=US&ROWNUMBER=39 POPPED HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39245824?TENANT=US&ROWNUMBER=51 POPPED HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39244011?TENANT=US&ROWNUMBER=62 POPPED HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39258823?TENANT=US&ROWNUMBER=81 POPPED SEE ATTACHED POPS2 I CAN FIND YOU PLENTY MORE. PLEASE INVESTIGATE. THANK YOU KEEF

NHTSA ODI 11400003