NHTSA complaint #11742451

Owner complaint summary

I am reporting a severe structural defect in the 2022 Model 3 front suspension and wheel hub assembly that poses an imminent threat of catastrophic failure. My vehicle is nearly new, with less than 30k miles. As the original, single owner who maintains this car, a critical failure of this nature is highly premature and indicative of a manufacturing defect rather than normal wear-and-tear. The issue manifests as a progressive clicking and popping noise from the front wheel area during operation. After noticing this sound, I took my vehicle to the dealership. The technician's inspection revealed that critical structural components were loose and failing. The technician explicitly warned me that this specific failure carries a direct risk of sudden wheel separation while the vehicle is in motion. This forced me to take immediate, emergency action right there at the dealership; leaving the shop without fixing it was simply not an option, as driving my car in that condition would have caused immediate and dangerous consequences on the road. A wheel separating or a suspension collapsing at highway speeds is an inherently fatal scenario that endangers my life, my passengers, and the public. This mechanical failure is highly similar to the defect described in NHTSA Number: 21V835000, which covered front suspension lateral links separating from the subframe and carries the same dangerous consequences. However, because my vehicle is a '22 model, Tesla refused to acknowledge the connection to that safety campaign and denied coverage under the drivetrain warranty. I was forced to pay over 800 out of pocket to resolve this hazard. While I could afford this, many drivers cannot. Tesla’s failure to expand their recall to the '22 model year means thousands of drivers are unwittingly operating a ticking time bomb. NHTSA must investigate this issue and force Tesla to expand the recall to include '22 vehicles before this known, fatal defect causes an an entirely preventable tragedy.