NHTSA probes 1.2 million Teslas over front suspension link failure complaints

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NHTSA has opened a preliminary investigation covering nearly 1.2 million Teslas.

Regulators received 156 complaints alleging front suspension link failures.

Owners reported hearing noises before failures but received no dashboard warnings.

Tesla is no stranger to recalls but oftentimes, it can send an over-the-air update as a remedy . This time won’t be the same if the NHTSA decides that a new recall is in order. The federal administration is investigating whether or not previous recalls from Tesla were large enough. If not, the fix could reach nearly 1.2 million cars with potentially faulty steering and suspension parts.

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The probe comes after more than 150 complaints alleging that the front suspension can fail and leave drivers without full directional control. It covers certain 2018-2020 Model 3 sedans and 2021-2023 Model Y crossovers, one of the largest defect investigations the automaker currently faces. Tesla has recalled similar vehicles before, but investigators believe these latest reports point to a different fault.

No Warning Before It Breaks

The action falls short of a full-blown recall , at least for now. The Office of Defects Investigation says that many owners reported no warning whatsoever before the suspension failed. Some complained of creaking or other noises beforehand, but the agency says the vehicles generally provided no visual warnings. Once the failure occurred, many vehicles became undrivable and had to be towed.

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One complaint included in the investigation offers a good example of the kinds of failures drivers are reporting. A Florida owner of a 2021 Tesla Model Y (NHTSA Complaint No. 11744359) said the SUV suffered a “complete failure” of the front lower lateral links, compliance links, and upper control arms at just 29,103 miles (46,837 km).

According to the complaint, there were no warning lights or messages before the failure, only a creaking sound while turning, especially in reverse. The owner also claimed the issue closely resembled an earlier Tesla suspension recall, but said their VIN was not included, leaving them responsible for the repair bill.

The Recalls That Came Before

Tesla has previously addressed front suspension issues through two separate recalls. Recall 21V-835 covered 2,791 Model 3s from the 2019-2021 model years due to a production issue, while Recall 23V-235 involved 422 examples from the 2018-2019 model years that experienced similar failures.

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That said, investigators say the complaints behind this latest probe extend beyond the scope of those recalls and “do not appear to be related to the production issue” that prompted them. Depending on what the NHTSA finds, this could turn into nothing or, conversely, one of the biggest recalls Tesla has ever issued.

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Photos: Tesla