NHTSA complaint #11733457

Owner complaint summary

What component or system failed or malfunctioned, and is it available for inspection upon request? The front windshield (Acoustic Glass) failed due to a spontaneous stress fracture. The crack originated from the edge of the glass without any external impact. The vehicle has been repaired, but the service records and high-resolution photos of the crack are available for inspection upon request. How was your safety or the safety of others put at risk? The spontaneous crack occurred suddenly during a heatwave, significantly obstructing the driver’s forward visibility. Furthermore, the crack expanded rapidly during a subsequent rainstorm and temperature change, compromising the structural integrity of the windshield and potentially interfering with the front-facing ADAS cameras (Autopilot/Safety features) located behind the rearview mirror. Has the problem been reproduced or confirmed by a dealer or independent service center? Yes. The problem was formally inspected and confirmed by the Tesla Burlingame Service Center. They issued a written evaluation report stating the damage was a "Stress Impact" (a manufacturing/structural defect) rather than a rock chip. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? Yes, the component was inspected by the manufacturer (Tesla Service Centers in both Burlingame and San Francisco). Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? No warning lamps or messages appeared. However, this vehicle was previously subject to a Heat Pump recall (22V045) related to defrosting issues, which may have contributed to long-term thermal stress on the windshield structure prior to this failure.