2016 Tesla Model X: ball joint or control arm failure

Filed May 16, 2025 · Suspension · FL

Sudden and catastrophic shearing of the driver side rear suspension arm (control arm). My understanding is all these cars from Tesla have aluminum suspension arms which causes identical and catastrophic failure of the vehicle during driving due to choice of Aluminum instead of stainless steel(SS). Aluminum has an ultimate tensile strength of only 90 MPa while SS can exceed 500 MPa. Since my car got disabled completely (motor gets disconnected from the wheel) I almost lost my life with vehicles coming at high speed from behind. I saw the same control arm failures with Tesla cars including S and 3 and X (like mine) all over the world. Here is an example of a very similar failure to mine on a model 3 in Norway : [XXX] The failure is so similar that even the wheel tilted inwards to the wheel bay just in my case due to the clean shearing of the aluminum bushing on the control arm. I would like to make sure these failures do not continue with Tesla and people's lives are not at risk and thus this report. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Feb 28, 2025 · Suspension · WI

Wheel tilted in when backing out of driveway turning due to control arm failure

Filed Aug 1, 2024 · Suspension · OR

What component or system failed or malfunctioned, and is it available for inspection upon request? Rear driver's side control arm failure during slow left-hand turn (~20 mph) from one road to another. A "clunk" noise was heard from underneath the car, like that of a rock striking the vehicle, and then the vehicle reported several errors regarding drive unit failure, brake failure, and stability failure. The vehicle automatically shifted to "P" and would not move. Upon exiting the vehicle, the rear tire was tilted in at a 45 degree angle and the control arm was broken open and a 1.25 inch piece of the control arm was on the road. How was your safety or the safety of others put at risk? The suspension failed at low speed (~20 mph) and in little to no traffic, with no option to move the vehicle to a safer area. Had the failure occurred at any other time (higher speeds, heavier traffic), the danger to life would have been catastrophic. Has the problem been reproduced or confirmed by a dealer or independent service center? The problem is evident in the broken component dangling from the under side of the vehicle. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? The Tesla Service Center - Salem has inspected the issue and stated that they do not have the capability of fixing the issue and that the issue is due to a collision. My Insurance has assessed the issue and determined they will not cover the issue as there was no collision involved in the damage. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? There were no warnings, messages, or other symptoms prior to the suspension failure.

Filed May 15, 2024 · Suspension · CA

Squeaking noise on the passenger rear side was noticeable when I am hitting the breaks then a thump sound as if I landed on some big pothole occurred. So I drove as slow as I can until we reach home. I inspected the vehicle and to my surprise the control arm had torn and the tires were hanging loose.

Filed Apr 16, 2024 · Steering, Suspension · 66,000 miles · IL

The contact owns a 2016 Tesla Model X. The contact stated while driving at various speeds, there was an abnormal squeaky and clunking sound coming from the front end of the vehicle. The vehicle was taken to the Tesla Service Center, where the front driver's side and the passenger's side front upper control arms links and bushings were replaced, and the four-wheel alignment was performed. Additionally, the contact stated while driving at various speeds, the steering wheel was significantly resistant. The vehicle was taken to the Tesla Service Center, where the intermediate lower steering column shaft was replaced. Additionally, the contact stated while driving 20-30 MPH and making a right turn, the steering wheel became significantly loose, causing the contact to lose steering control. Additionally, the wheels failed to respond as needed. The contact stated that the vehicle was perpendicular to oncoming traffic at the time of the failure. The contact parked the vehicle and had the vehicle towed to the Tesla Service Center, where it was being diagnosed. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 66,000.

Filed Mar 26, 2024 · Driver assistance, Suspension · CA

Car tends to brake in autopilot without having any car in front causing jolt feeling and dangerous scenario for vehicles behind. Suspension work like upper control, half shafts, ball joints, toe and struts been replaced 5 times. One time entire wheel came off.

Filed Oct 20, 2023 · Suspension · CA

Aluminum lower control arms break under normal driving conditions

Filed Oct 20, 2023 · Suspension · CA

Left front lower control arm broke when parking.

Filed May 3, 2023 · CA

On August 30, 2022 between 8:30 and 9:00 a.m. the driver of a 2016 Tesla X, was traveling at highway speeds in the number one lane. The fore link failed when the driver applied the vehicle’s brakes in response to a vehicle in front of her abruptly braking for a hazard ahead. A grinding noise came from the drivetrain and the vehicle rapidly slowed involuntarily. The driver was able to navigate across several lanes of traffic to the right shoulder. The vehicle remained inoperable at the side of the freeway until it was later towed to Tesla, Inc. for repair. The nature of the incident was reported to Tesla Inc. Tesla, Inc. diagnosed the issue and found front left fore link to be broken at the ball joint. The technician found additional damage to : (1) the coaxial cable that leads to the left rocker panel; (2) the front aero shield; (3) front left fender liner (missing); and (4) main harness. Later, damage was discovered to the A/C compressor. Notably, Tesla Inc. inspected the vehicle braking system twice in the two months preceding the incident. On June 28, 2022, Tesla Inc. replaced the front brake pads. On August 4, 2022, Tesla Inc. inspected the tire pressure and condition and did not recommend rotation. No warnings were displayed. Co-owner spoke with a service manager at Tesla Inc. regarding Service Bulletin 17-31-001, indicating that Model X vehicles built in 2016 may have been manufactured with front suspension fore links that may not meet Tesla strength specifications. Nevertheless, Tesla, Inc. refused to cover the repairs under the Drivetrain Warranty or goodwill. The co-owner later learned that the Office of Defects Investigation (ODI) of the federal safety agency has opened Preliminary Evaluation (PE20-020) regarding this issue. Co-owner also requested that Tesla, Inc. replace the right fore link without charge. After Tesla Inc. refused to do so, co-owner paid for the replacement out of pocket.

Filed Apr 16, 2023 · Suspension · OR

The control arm joints of the Model X started to squeak under warranty. Under warranty, they "Reseal Area Around Both Front Upper Control Arm Ball Joints With Urethane (Model X)" which they knew didn't fix the problem from looking Tesla forum. It just masks the problem for another 1-2 years and when the car is out of warranty, they now offer a fix which is to replace the entire control arm joint which is around $1k per side. There is a known issue with Model X suspension. It looks like other models have had a recall for similar issues.

Filed Apr 15, 2023 · Steering · SD

The front control arms broke. I had it in for recall work and asked them to check the rear control arms. We had just gotten new tires on it and the tire shop recommended we bring it in to have Tesla look at the rear control arms. Tesla said they looked good and then last minute they said the front control arms were broken. Not sure how that happened, but it seems to be a common problem with the 2016 model xs. Paid 637.94 for the repair. Since then, our power steering has been almost non existent.

Filed Mar 11, 2023 · Seats, Steering · NY

The second tow captain rear seats are not bolted securely. The seats both rock forward and back. I brought it up to Tedla service and the representative came back with, The car is 6 years old. So does that mean Tesla Model X captain seats begin to fail after 6 years? The other issue is a steering issue. When I steer left or right I hear a clunking noise. It's not related to the control arm as it is a known issue. The odd thing is when it rains the noise goes away which I believe it may be related to a lubrication issue. When the vehicle dries up after a day or two the noise starts again.