2018 Tesla Model 3 Suspension

Car was making clunking sound, so made an appointment with service center. Before appointment, clunking sound stopped. Around the same time the clunking stopped we found a bolt in the driveway. Took into service and was told a bolt was missing from the lower lateral link which sounds quite concerning. I'm told by others had both bolts fallen out the wheel would have tipped inward or outward and damaged the fender and possibly caused an accident. I searched recall notices and I found recalls and/or bulletins with the same problem in similar but not the same VIN range as our vehicle and have read of others with similar problems not covered by recalls. There had been no previous work done on the front suspension.

The contact owns a 2018 Tesla Model 3. The contact stated that after taking the vehicle for service, the contact was made aware that the front suspension lateral linkage bolt had detached and that the bolts were damaged. No warning lights were illuminated. The vehicle was repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 23V235000 (Suspension); but the VIN was not included. The manufacturer was notified of the failure, and a case was opened. The failure mileage was approximately 51,000.

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

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

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.

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.

During the first 5 years of ownership and while under warranty I experienced many creaks in the suspension that did not sound normal. I took it to the Tesla service center many times but was often unable to reproduce the sound when needed and told there was nothing they could do. When a technician did finally hear the sound, Tesla resealed the ball joints at no cost. This was a short-term fix and the problem persisted. After doing some research on my own I have found that this is a known defect in my car model along with the control arms often failing which can cause loss of control of the car. I am now over a year past my warranty and the control arm did in fact fail at 46,000 miles. I experienced a loud creak/rubbing sound when driving over any uneven surface. This happened overnight and was not due to any incident. When I brought the car for repairs and inquired about all of this I was told that this is normal wear and tear and that because it is such a heavy car it is not an unusual repair. I pressed the technician sharing the information I had researched and he said that he would not charge me for the labor. Because this is a known defect and I have read about many owners having to replace the control arms multiple times (often at very low mileage), I continued to argue for no cost to me which was finally granted. That being said, Tesla definitely knows it has a defective product and is doing everything it can to make owners responsible for any cost.

The first time was rattling and squeaking from front driver's side wheel. It got progressively worse so I took it in and they replaced the control arms. About 10 months later the rattling is back. This time Tesla says it's a different problem. I need to replace the lateral links, the compliance links and get a wheel alignment.

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

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.

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.

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

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.

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.

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.

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.

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)

Front suspension arm dislocated while driving (at 15mph). Could have been fatal had I been on the highway. Bolt connecting suspension was not broken, must have just come loose. I believe this is similar to the recall notice 21V-835, but that only covered years 2019-2021. My car is a 2018, one of the first ones released. This should have also been included in the recall. Tesla told me my car is out of warranty and to take to a body shop.

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.

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.

The passenger and driver side bolts connecting the shock strut to the lower control arms have come loose. The passenger side nut is missing and the bolt has almost fallen out, just hanging on by a thread. Can make driving dangerous by increasing instability.

Bolt connecting lower control arm to the sub frame fell out as it wasn’t torqued/fastened properly during manufacturing. This caused suspension to rattle and cause wheel alignment warnings to go off.

The driver side front left suspension lateral link fasteners (bolts and nuts) completely fell off, allowing the lateral link to separate from the sub-frame. This occurred at low speed attempting to turn into my home driveway and resulted in the front left fender resting only on the tire. Significant body damage was incurred, with the fender and the driver door coming in contact and obstructing initial exit of the vehicle. Tesla claimed that my car was not included in any recall, even after escalation within the service department and my insistence that they cover the costs of the repairs. They refused repeatedly. I ended up paying $2037.08 for the suspension repairs, and additional $3000 for body repairs. This would have been a catastrophic incident and failure had I been at highway speeds, which I was literally 5 minutes prior to the suspension failure.

The front left control arm (lateral link) of my Model 3's front wheel just came completely off (bolts unscrewed) without any incident. It fell to the ground and preventing my car from steering properly and was dragging on the ground. The car couldn't drive properly and needed to be towed to the Tesla service center. This could have easily caused a fatal accident by causing the car to suddenly not be able to steer and drive properly. I had the vehicle towed to the Tesla service center and the engineers did not know how or why the bolts were unscrewed and came out. The Tesla service center forced me to pay out of pocket since my vehicle had 70K miles and was out of warranty. They refused to accept it as a manufacturing safety defect.

The main bolt that holds together the wheel and body on the driver side fell off while driving, resulting in wheel falling off and car not able to operate safety. The bolt is marked with kxv109. This caused damage to the entire subframe assembly. This could have been a very terrible accident if I was driving at a higher speed. On October 27, 2022 I noticed an odd sound from my steering wheel which I reported to Tesla and had my car in for service and was told that nothing was wrong and everything worked as expected, so I continued to drive my car. My car’s wheel fell off on January 20, 2023, the bolt that held the wheel to the body completely broke off and fell on the ground.