NHTSA complaint #11737610

Owner complaint summary

Component/System Failure: Total failure of the Autopilot ECU (DAS Computer) and the Front-End Module (FEM) wiring harness. Incident Description: My 2021 Tesla Model 3 (37,000 miles) experienced a catastrophic and "silent" failure of the entire vehicle vision suite and all active safety systems. A Tesla Service technician (Warrington, PA) inspected the vehicle and confirmed the root cause was a factory-defective (crimped) internal coaxial cable in the wiring harness. This manufacturing defect caused an electrical short that destroyed the primary safety-critical computer. Safety Risk: This failure resulted in a direct violation of FMVSS 111 (Rear Visibility), as the backup camera was rendered completely inoperable. Furthermore, all collision-avoidance features—including Automatic Emergency Braking (AEB), Forward Collision Warning, and Blind Spot Monitoring—were disabled. Critical Safety Concern (Silent Failure): The vehicle provided zero driver-facing alerts, dashboard warnings, or lamps to indicate that these safety systems were offline. I unknowingly operated a vehicle that was non-compliant with federal safety standards and lacked all primary crash-avoidance technology. The failure codes (APP_w045 and VCFRONT_a158) were only discoverable by manually entering the vehicle's "Service Mode." Manufacturer Status: Tesla Service has confirmed the hardware failure and the wiring defect but is currently refusing to cover the $2,800 repair cost, despite the failure involving systems currently under federal recall (SB-26-00-016). I am reporting this because a factory wiring defect causing a total, silent failure of federally manda