2016 Tesla Model S suspension problems

Filed Oct 21, 2026 · Suspension · CA

In October 2026, my 2016 Tesla Model S experienced a sudden structural failure of the left front suspension fore link while driving on Highway 101. The fore link fractured at its connection to the steering knuckle, allowing the front wheel to shift rearward and become lodged against the wheel-well liner. This made it difficult to turn the steering wheel, substantially impairing my ability to control the vehicle. I was able to maneuver the vehicle onto the highway shoulder, but the failure created a serious risk of a collision. There were no dashboard warnings or error messages before the failure. I had previously noticed abnormal noises and vibration from the front suspension. The vehicle had approximately 79,000 miles at the time of the incident. Tesla inspected the vehicle at its Palo Alto Service Center and replaced both front lower fore links and both front aft links, followed by a four-wheel alignment. The repair was completed on October 20, 2026. I retained the original suspension components and confirmed that the fore links were part numbers 1041570-00-A (left) and 1041575-00-A (right). The left fore link exhibits a fracture at the knuckle-side connection. I have photographs documenting the failure and identifying labels, and the physical components are available for the federal safety agency inspection upon request. These are the exact part numbers identified in the federal safety agency investigation PE20-020, which documented 426 fore-link failures involving these components. In its August 2024 closing report, the federal safety agency recommended expanding Tesla Service Bulletin SB-17-31-001 to all vehicles equipped with the affected fore links, noting that approximately 75% of documented failures occurred outside the original bulletin population. Tesla confirmed that my vehicle was not covered by the existing service bulletin, and I paid $2,262.68 for the repair. I am reporting this additional, physically documented failure involving impaired steering control and requesting that the federal safety agency consider whether furth

Filed Oct 8, 2026 · Steering, Suspension · MN

Rear left control arm failed while driving causing loss of steering and suspension

Filed Jun 16, 2026 · Suspension · 108,000 miles · AZ

The contact owns a 2016 Tesla Model S. The contact stated that approximately six days after purchasing the vehicle, while driving approximately 45 MPH, the vehicle drove over a bump in the road, and a grinding sound was heard coming from the vehicle. The contact stated that after driving over a bump in the road, the vehicle felt different while driving. The vehicle was taken to an independent mechanic, who reportedly observed significant corrosion and rust affecting the suspension system and advised the contact that all suspension components needed to be replaced. The independent mechanic advised the contact not to drive the vehicle due to safety concerns and indicated there might be structural damage to the vehicle. The contact stated that after the suggestion, the contact continued operating the vehicle. The following day, the vehicle was taken to the dealer where the vehicle was purchased, and the contact was advised that the failure was associated with worn brake pads. The dealer replaced the brake pads. The contact believed that additional repairs may have been performed but was not advised of any other work completed. The vehicle had not been modified and had not been inspected by Tesla. The contact believed that the vehicle may have an inaccurate odometer reading; however, no evidence was available to support the concern. The contact remained concerned that the corrosion and possible structural damage might exist within the suspension system even though the brake pad was replaced. The failure mileage was approximately 108,000.

Filed May 8, 2026 · Suspension · CA

Driver side rear control arm broke in half propagating along what appears to be a weld seam line for this hollow aluminum suspension part. It is incredible that a critical safety component holding a 5,000 pound curb weight vehicle was allowed on the car. The potential situation of a complete lower control arm break while driving at highway speeds is beyond imagining. Not only would such a situation endanger occupants but all other vehicles in the vicinity. This vehicle has never been in an automobile accident. It has 120,000 miles. It has never been used off road or for commercial usage. My wife and I are the original owners and only drivers.

Filed May 6, 2026 · Suspension · MA

On a side street approximately 1/4 mile before we were going to enter a highway the car suddenly resisted motion substantially and I had to immediately pull to the side. I tried reverse and the resistance was higher, I put it back in forward and it released. However, I immediately but slowly headed for my service station 2 miles away. A warning message appeared just as I brought the car to a stop at the station, but I did not notice what it said as I was being directed to move the car to a parking spot. Before I could fully back the car into the spot the rear wheel collapsed. The rear control arm failed and has been replaced. I have retained the failed control arm. Photos attached of the part as well as the rear wheel when it collapsed. If the initial resistance had occurred one minute later, I would have been on the highway and could have lost control of the vehicle. A serious accident would have been likely risking our safety and any others our car would have collided with. Note: This is the second suspension part failure on this car. The first was also reported to the federal safety agency.

Filed Dec 1, 2025 · Suspension · 60,348 miles · CA

The contact owns a 2016 Tesla Model S. The contact stated that while driving approximately 10 MPH and making a right turn there was an abnormal sound coming from the front passenger’s side of the vehicle. The contact stated then started to smell a burning rubber odor. The contact was able to stop the vehicle. The contact stated that there was no warning light illuminated. The contact became aware that the front passenger’s side wheel had seized in a right turn position and was rubbing against the wheel well. The contact had the vehicle towed to the residence. The contact had not taken the vehicle to a local dealer or independent mechanic to be diagnosed or repaired. The manufacturer was not informed of the failure. The contact researched online and related the failure to the federal safety agency Action Number: PE20020 (Suspension). The failure mileage was 60,348.

Filed Oct 6, 2025 · Suspension · CA

Car was making a rattling noise and no indication on the car indicating that it was a suspension issue. Drove for a few months without realizing that it was a suspension and hence a safety problem. Took it to the Tesla Service Center and they diagnosed as a suspension problem and said that it was unsafe to drive the car. The repair at Tesla to replace the links (aft, fore, sway bar) and spring/damper assembly was $5809.71;

Filed Jul 26, 2025 · Suspension · CA

I was backing out of a parking space and the front driver side fore link broke. Internet search reveals this is a known issue associated with Tesla Model S during the period mine was manufactured (February 2016), caused an investigation & service bulletin from the federal safety agency, and a recall in China, hence I wanted to report this occurence.

Filed Jun 14, 2025 · Suspension, Wheels · IL

on 5/20/25, I had my Tesla repaired as I had suspension issues. They repaired my car to rectify my suspension for both my front and rear tires. Then on 6/12/25, I was driving on the highway and going about 70-75 mph when I heard a huge pop. No warning indicators came on and something did not feel right. I figured nothing else came of it. I was about 30 miles away from home and when I got home, my tire was pushed inward. I was concerned on whether this was related to a bad repair since it was so soon to my previous repair and they indicated that they did not touch that area. After they saw my video, they indicated that the lower control arm of my rear tire broke and they indicated that this was just a damaged component. My biggest concern is that if this issue was not related to the repair work done a month ago, this could be bigger issue as I could have been very concerning that this part broke when I was driving at high speeds and I think it's warranted to check on the quality of the component. In my 40 plus years of driving, I have never experienced this happened to me. If you need documentation or video of how the tire and the axle looks, I can forward it to you. The vehicle has only been inspected by the Tesla Dealership service center and as stated earlier, there weren't any warning signs or messages that showed as I specifically was looking for it when I heard the loud pop.

Filed Nov 14, 2024 · Suspension, Wheels · IL

In December of 2023, my RIGHT rear axle broke when I accidently hit a curb. The car was repaired at the Tesla collision center. On last Tuesday, November 12, 2024, I heard a noise while braking. I continued to drive, but next time I needed to use brakes, I had a sensation that the brakes were failing, and I wouldn't be able to stop. The brakes eventually engaged, and I was able to stop the vehicle. I went on an expressway and drove as slowly as possible, maintaining a long distance from the vehicles in front of me and using regenerative braking as much as possible, being aware of a possibility of brakes failure. I got home safely on that day, however, the next day, when I was backing out of the garage, I heard a screeching noise. When I inspected the vehicle, I discovered that the LEFT rear wheel was misaligned, looking exactly like the right rear wheel after the right rear axle broke. Although this defect hasn't been inspected by a technician yet, I am virtually certain that it's the same problem that I had before, now occurring on the opposite side. This means that I was likely driving with a broken axle, which could've resulted in a serious accident. As I mentioned, this is the second instance of the same defect affecting my vehicle, which, in my opinion, is indicative of a serious manufacturing defect that needs to be addressed. The vehicle hasn't been repaired yet and is available for inspection. There were no warning lamps, messages or other symptoms prior to the failure.