Tesla Recalls All Cybertrucks in the U.S. Due to Adhesive Issues

[PCauto] Recently, the National Highway Traffic Safety Administration (NHTSA) announced that Tesla is recalling 46,096 Cybertrucks, produced between November 13, 2023, and February 27, 2025, which nearly encompasses all Cybertrucks. The recall is directly attributed to a defect in the adhesive used on these vehicles, posing a risk of body panel detachment and severely threatening road safety.

According to NHTSA, the recall primarily involves the Cant Rail trim of the vehicle's roof. Due to insufficient durability of the structural adhesive, adverse environmental factors have degraded the bonding agent used to secure the stainless steel exterior, which may cause the trim panel to separate and detach during vehicle operation. Should this occur, the falling panels could create significant safety hazards for vehicles traveling behind, greatly increasing the likelihood of serious traffic accidents.

In response to this issue, Tesla swiftly implemented a corrective plan, deciding to replace the affected components, such as the roof rails, free of charge for impacted owners. The new design employs a more environmentally resistant adhesive and reinforces the connection between the stainless steel panel and vehicle structure by welding studs onto the panels, thereby enhancing the stability of the components and reducing the risk of detachment.

Starting from March 21, Tesla has fully implemented the updated components on the production line, and any vehicles that are still in Tesla’s possession and yet to be delivered will undergo modifications before being handed over.

However, this isn’t the first time the Cybertruck has made headlines due to quality issues. Since its delivery began in November 2023, the Cybertruck has faced multiple recalls. In November 2024, Tesla recalled 2,431 Cybertrucks due to a malfunction in the drive inverter, which could lead to sudden loss of power, significantly increasing the risk of collision.

Additionally, the Cybertruck has been recalled multiple times for issues such as dashboard display malfunctions, single-wiper failure, and loose side trim on the bed. Some of these issues have been addressed through OTA software updates, but hardware defects like the adhesive failure causing body panels to detach must be resolved through factory repairs.

The frequency of these recall events has raised significant concerns in the market regarding Tesla's product quality and production management capabilities. Analysts have pointed out that while the stainless steel body of the Cybertruck offers a futuristic and technological appeal, contributing its popularity among numerous consumers, it imposes high demands on assembly processes, particularly the adhesive application.

In an effort to accelerate production speed, Tesla may have compromised the rigor of its testing procedures, failing to adequately validate the long-term stability of the adhesive under various environmental conditions, leading to the current large-scale recalls. Despite Tesla's assertions that the new adhesive and reinforcement strategies will completely resolve the issue and that improvements have begun on the production line, consumer and market trust in the quality of their products has taken a significant hit.