Exhibit D · safety record
Recalls
Eleven NHTSA campaigns in twenty-seven months — what each one actually covered, how it was fixed, and why the populations can't be added up.
The denominator problem. Recall populations are the 'number of potentially involved' figures from each Part 573 filing at report date. They cannot be summed into a count of unique trucks: campaigns overlap heavily (most cover the same early-production vehicles), several are multi-model fleet totals in which Cybertruck is a small subset, and populations grow with cumulative production at each filing date. The 63,619 population of 25V-699 doubles as a Tesla-confirmed cumulative production figure as of October 2025 because it covered every Cybertruck built to that date on affected software.
Two disciplines govern this page. First, scope: some campaigns covered nearly every truck built (cant rail, parking lamps), others a few thousand (inverter) or a few hundred (wheel studs) — “Tesla recalled every Cybertruck for X” is only occasionally true, and each card below states its own population. Second, remedy honesty: an over-the-air software push and a physical service visit are different burdens on owners and on Tesla, and the record shows seven of eleven campaigns needed hands on metal.
The most consequential finding in the record is the cant-rail campaign (25V-170): the Part 573 filing states the structural adhesive joining the stainless trim to the body is susceptible to environmental embrittlement, and the remedy adds a different adhesive plus a welded stud and clamping nut — a mechanical fix for a bonding strategy that didn’t survive the field.
Showing all 11 entries.
All Cybertruck-inclusive NHTSA recalls, 2024–2026
Warning-light font too small (FMVSS 105/135)
- Affected population
- 2,193,869 fleet-wide, multi-model
- Population scope
- Fleet-wide total across Model S/X/3/Y plus 2024 Cybertruck; the Cybertruck share is a small subset.
- Defect
- Brake, park, and ABS visual warning indicators rendered at ~1.5 mm letter height against a 3.2 mm regulatory minimum.
- Remedy
- Over-the-air software update increasing indicator font size.
- Sources
- [NHTSA]
Accelerator pedal pad may dislodge and trap the pedal
- Affected population
- 3,878
- Population scope
- All Cybertrucks built November 13, 2023 – April 4, 2024.
- Defect
- An unapproved assembly lubricant reduced pad retention; a dislodged pad could wedge the pedal into interior trim. Deliveries were paused while the fix was staged. The brake pedal cuts drive torque even with both pedals pressed.
- Remedy
- Physical replacement or rework of the accelerator pedal assembly.
Front windshield wiper motor controller failure
- Affected population
- 11,688
- Population scope
- Cybertrucks built November 13, 2023 – June 6, 2024; Tesla estimated 2% actually defective.
- Defect
- Electrical overstress to the wiper motor gate driver during supplier functional testing could cause the wiper to stop working, reducing visibility.
- Remedy
- Physical replacement of the wiper motor.
- Sources
- [NHTSA]
Sail applique trim may separate at speed
- Affected population
- 11,383
- Population scope
- Cybertrucks built November 13, 2023 – May 26, 2024; Tesla estimated 1% actually defective.
- Defect
- Adhesive installation of the trunk-bed sail applique could fall below specification; a detached panel is a road hazard for following traffic.
- Remedy
- Physical replacement or rework of the applique for proper adhesion.
- Sources
- [NHTSA]
Rearview camera image delayed after shifting to Reverse (FMVSS 111)
- Affected population
- 27,185
- Population scope
- Model-year 2024 Cybertrucks.
- Defect
- The rear image could remain blank up to roughly 6–8 seconds after selecting Reverse; the standard requires display within two seconds.
- Remedy
- Over-the-air firmware update (2024.32.5.2 or newer).
- Sources
- [NHTSA][CBS News]
Drive inverter MOSFET fault causing loss of propulsion
- Affected population
- 2,431
- Population scope
- Only Cybertrucks carrying a specific MOSFET part family in the drive inverter — not the whole fleet.
- Defect
- A faulty inverter could stop producing torque without prior warning; the UI alerts after loss of torque with an instruction to pull over.
- Remedy
- Physical drive-inverter replacement (service from December 2024; owner letters January 2025).
TPMS malfunction telltale fails to persist (FMVSS 138)
- Affected population
- 694,304 fleet-wide, multi-model
- Population scope
- Multi-model fleet total (Model 3/Y plus the 2024 Cybertruck subset on noncompliant software); the exact Cybertruck-only count requires VIN-level lookup.
- Defect
- A software release caused the tire-pressure malfunction telltale not to remain illuminated between drive cycles as the standard requires.
- Remedy
- Over-the-air update to compliant software releases.
- Sources
- [NHTSA]
Cant rail stainless panel may delaminate and separate
- Affected population
- 46,096
- Population scope
- Cybertrucks built November 13, 2023 – February 27, 2025 — nearly the entire fleet to that date. 151 warranty claims possibly related at filing.
- Defect
- The cant rail joins an electrocoated steel stamping to a stainless panel with structural adhesive. The Part 573 remedy section states the original adhesive is susceptible to environmental embrittlement; a separated panel is a road hazard. A delivery containment hold preceded the filing.
- Remedy
- Physical replacement with an assembly using a different structural adhesive plus mechanical reinforcement — a stud welded to the stainless panel clamped with a nut.
Front parking lamps exceed FMVSS 108 brightness limits
- Affected population
- 63,619
- Population scope
- Every Cybertruck built November 13, 2023 – October 11, 2025 on software prior to 2025.38.3 — a Tesla-confirmed cumulative production figure as of the filing.
- Defect
- Vehicle-controller software could command parking-lamp intensity above the regulatory maximum, potentially distracting other drivers.
- Remedy
- Over-the-air update to software 2025.38.3 or later.
- Sources
- [NHTSA][USA Today]
Service-installed off-road light bar may detach from windshield
- Affected population
- 6,197
- Population scope
- Only trucks on which Tesla service installed the optional off-road light bar; 619 warranty claims at filing — a 10% estimated defect rate.
- Defect
- A primer mix-up in field service (incorrect surface primer) could leave the accessory light bar poorly bonded; detachment creates a road hazard.
- Remedy
- Physical inspection; replacement with tape plus positive mechanical attachment, or retrofit of mechanical attachment where intact.
- Sources
- [NHTSA][USA Today]
Brake-rotor stud-hole cracking on 18-inch steel wheels
- Affected population
- 173
- Population scope
- Only trucks equipped with optional 18-inch steel wheels; Tesla attributed the condition to an August 2025 change-management error and stopped producing the wheel configuration in November 2025.
- Defect
- High-severity road inputs could strain rotor stud holes into cracks; propagation could eventually separate a wheel stud from the hub, affecting controllability.
- Remedy
- Physical replacement of front and rear rotors, hubs, and lug nuts with higher-durability parts.
- Sources
- [NHTSA]
Open investigations (not recalls)
FSD performance in reduced-visibility conditions (Preliminary Evaluation)
Opened across roughly 2.41 million Tesla vehicles with FSD, including 2023–2024 Cybertrucks, examining whether FSD detects and responds to reduced roadway visibility such as sun glare and airborne obscurants.
Sources: [NHTSA]
FSD reduced-visibility investigation upgraded to Engineering Analysis
Escalated March 2026 to cover roughly 3.2 million vehicles including Cybertruck, with 80 logged incidents through December 2025. An open investigation is not a recall or defect finding.
Sources: [NHTSA]