Tesla Model S ball joint problems

Filed Oct 30, 2026 · Suspension, Wheels · OH

At approximately 62,600 miles the lower rear reward control arm sheared off which then required a repair cost of $2000.00. The car became essentially un-operatable, it could only move forward and there was the distinct possibility of the wheel separating from the car

Filed Oct 8, 2026 · Steering, Suspension · MN

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

Filed Aug 2, 2026 · Suspension · IL

●Odometer at time of failure: approximately 204,078 miles ●Date of failure: XXX ●Location of failure: Owner's residential driveway, [XXX] Component Suspension — Front — Lower Control Arm / Front Fore Link / Front Aft Link (right side) Description of the Incident On XXX, at approximately 1:00 PM, I began backing my 2015 Tesla Model S out of my residential driveway. The vehicle was moving at less than five miles per hour. There was no impact with any curb, pothole, road debris, or other object. As the vehicle moved rearward, there was an audible pop from the right front, and the top of the right front tire visibly sank inward (negative camber) as the wheel well collapsed. The vehicle became nearly undriveable and had to be moved slowly to a repair facility approximately 7 miles away. No crash occurred. No injuries occurred. No emergency response was required. However, had this failure happened at highway speed rather than in the driveway, the safety consequences could have been significant. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

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 Feb 15, 2026 · CA

I am reporting a serious safety defect regarding the front control arms on my 2017 Tesla Model S (VIN: [XXX] ). The front control arm bushings are failing, with visible cracking and tearing, as documented by a certified mechanic. These failures directly compromise vehicle steering, handling, and safety, creating a high risk of loss of control or accident. Tesla has issued a known service bulletin related to this issue, yet refused to perform repairs free of charge, despite acknowledging the bulletin exists. Timeline of Communications and Attempts to Resolve: Dec 2015 – First reported issue to Tesla Service Center. Inspection was refused without a payment of $270. Tesla claimed the vehicle was out of warranty and refused free inspection or repair. Independent Mechanic Inspection – Confirmed front control arm bushings are cracked/ripped; photos were taken. Dec 27, 2025 – Email sent to [XXX] . Received a call from a local Tesla center stating nothing could be done because the car was out of warranty. I explained it is a safety issue, but it was disregarded. Jan 10 and Jan 18, 2026 – Follow-up emails sent to [XXX] , but no response was received. Jan 23, 2026 – Email sent to [XXX] , documenting safety concerns and service bulletin reference; no acknowledgment or response was received. I and Tesla have all the emails amd photos but unfortunately I was nit able to attach. If requested I can email or fi d out ways to shareholders. Please let me know. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Feb 1, 2026 · Suspension · MO

I pulled into a parking lot, and noticed that my passenger side rear wheel was leaning into the car. Luckily I was next to a Firestone and the mechanic told me the rear control arm broke off. Had I have been driving even for 2 more minutes, the wheel would have came off completely. When I pulled in, there was no noise, vibration, or any other indication that something was wrong. I know for a fact I didnt hit any curbs or large potholes. It was a normal drive.

Filed Nov 23, 2025 · Steering, Suspension · FL

I am reporting multiple safety-related defects on my 2017 Tesla Model S (VIN [XXX] ) that were present at the time of purchase but not disclosed by the selling dealer (Starling Ford, Titusville, FL). A certified independent EV repair facility (The Electrified Garage) inspected the vehicle on 11/17/2025 and documented the following safety defects: • failing/worn suspension components (control arms, thrust arms, cracked bushings) • torn sway-bar link boots • inoperative right-rear window regulator • driver window contacting internal wiring harness • moisture in the rear inner tail lamp • previous A/C drain blockage causing interior water intrusion These issues pose risks related to steering stability, electrical safety, visibility, and structural integrity. All of these conditions existed prior to the sale and were not disclosed. I am requesting the federal safety agency to log this complaint for federal safety review as these defects involve suspension, electrical moisture intrusion, and visibility issues that may impact the safe operation of the vehicle. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Nov 22, 2025 · Steering, Suspension · FL

Upon purchasing the vehicle, I discovered multiple critical safety defects that were not disclosed at the time of sale and were confirmed by an independent EV specialist (Electrified Garage). These defects include worn and failing front and rear suspension components (control arms, thrust arms, and cracked/damaged bushings), a failing sway bar link boot, and a malfunctioning window that makes contact with the internal wiring harness. The suspension defects create instability over bumps and uneven roads, producing clunks, shifting, and vibration that affect steering control and overall stability. These issues present a risk of suspension failure while driving, which could cause loss of control. The window/wiring contact also poses a potential electrical hazard if the harness becomes damaged. The independent inspection documented that these defects existed before I took possession of the vehicle. The dealer did not disclose any of these issues, and the defects were not visible during a standard test drive. I am reporting this because the suspension defects directly affect vehicle handling, safety, and crash-avoidance capability. I want the federal safety agency to be aware in case similar defects appear in other vehicles of the same model/year.

Filed Jul 6, 2025 · Body · MD

Front impact bumper separated from mount on one side due to rust. Noticed a noise from front of car when going over small bumps in the road. If we had been in an accident, the impact bumper would not have provided adequate protection for the passengers or vehicle components near the drivers front where the mount had separated from the bar. No other inspections have occurred. Pictures and info can also be found here: [XXX] Issue found during replacement of upper control arms. (image has an upper control arm that was removed from the same car at the same time with little/no rust) INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)