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Tesla · Known Issues

2025 Tesla Cybertruck Problems: 6 Known Issues

2025 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026

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Issue summary

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2025 Tesla Cybertruck has 6 documented known issues, with 2 rated critical. The most serious are Cant Rail Stainless Trim Panel Delamination and Detachment (Recall 25V-170) ($0-$0 repair) and Power Conversion System (PCS) Failure Kills AC/Home Charging and 48V DC-DC Supply ($2,000-$4,500 repair). Across all issues with published estimates, repair costs range from $50 to $4,500. DIY maintenance guides at au7o.io.

In This Article

  • Cybertruck Exterior3
  • Cybertruck Electrical1
  • Cybertruck Body/Panels1
  • Cybertruck Suspension1
  • Recalls11
  • FAQ
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In This Article

  • Exterior3
  • Electrical1
  • Body/Panels1
  • Suspension1
  • Recalls11
  • FAQ

All 6 Known Issues

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ALL YEARS202620252024

On the 2024-2025 Tesla Cybertruck, the cant rail is the stainless-steel exterior trim panel running along the upper edge of the vehicle between the windshield and the bed. It is bonded to the body with structural adhesive. Tesla determined the adhesive used in production is susceptible to environmental embrittlement — repeated wet/dry and freeze/thaw cycling degrades the bond — allowing the panel to delaminate and separate from the truck, potentially at highway speed where it becomes a road hazard for following traffic. Roughly 46,000 Cybertrucks built between Nov 13, 2023 and Feb 27, 2025 were recalled in March 2025, which was essentially the entire production run at that point. Owners had been reporting lifting edges, wind whistle from the roofline, and visible gaps at the panel joint before the recall was announced.

Common Symptoms

  • Stainless trim panel along roofline lifting or peeling at the edge
  • New wind noise or whistling from the upper windshield area at highway speed
  • Visible gap between cant rail and body
  • Panel detached while driving

How to Fix

Recall 25V-170 remedy performed free at Tesla Service: the cant rail is replaced with a panel bonded using a non-embrittling structural adhesive plus added positive mechanical fasteners so the panel cannot separate even if the adhesive degrades. Check VIN status on Tesla's recall page or NHTSA. If you see a lifting edge or hear new wind noise from the roof line before your appointment, do not attempt a DIY adhesive repair — get it in immediately, as a departing panel at speed is a genuine hazard.

Typical repair cost:$0 - $0

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

On the 2024-2025 Tesla Cybertruck, the accessory off-road light bar mounted above the windshield was bonded using the wrong adhesive, allowing the bar to loosen and detach from the vehicle and fall into the roadway as a hazard to following traffic; Tesla recalled 6,197 Cybertrucks over it. Separately and persistently, owners report the light bar housing filling with condensation after rain or a car wash; on some units the moisture never evaporates, indicating the enclosure seal or vent is not working. Trapped water inside an LED bar corrodes the drivers and connectors over time and produces a permanently fogged lens.

Common Symptoms

  • Light bar loose, shifting, or rattling on the roof edge
  • Light bar detached while driving
  • Water or fog visible inside the light bar lens after rain
  • Condensation inside the housing that never clears
  • One or more LED segments dim or dead

How to Fix

For the detachment recall, Tesla replaces the light bar free of charge with a unit secured using correct bonding tape plus a positive mechanical attachment so it cannot fall off if the adhesive lets go. For condensation, document it with photos taken within a day of the rain event and open a service request — service has been replacing fogged bars under warranty; a bar that stays wet has a failed seal and cannot be permanently dried out in place. Confirm your mounting is the post-recall mechanically fastened version before assuming the bar is secure.

Typical repair cost:$0 - $0

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

On the 2024-2026 Tesla Cybertruck, owners began reporting small orange flecks across the stainless body panels within days of delivery — in several documented cases after only a couple of days of driving in rain. The panels are uncoated stainless with no paint or clearcoat, so anything that lands on them stays on them. In most cases this is not the stainless itself corroding but free-iron contamination embedded in the surface — brake dust, iron particles picked up during rail transport, grinding swarf from shop tools, or industrial/rail fallout — which then rusts and stains the panel. Once embedded, that iron can also break down the passive chromium-oxide layer locally and initiate real pitting if left alone. Trucks in road-salt regions and those with magnets stuck to the exterior show it worst. Tesla's position is that it cleans off and does not affect structural integrity, which shifts the maintenance burden onto the owner.

Common Symptoms

  • Small orange or brown specks across body panels
  • Spots appearing after rain or a car wash
  • Staining concentrated on horizontal surfaces and near wheel arches
  • Discoloration under or around magnets placed on the body

How to Fix

Treat it as free-iron contamination, not paint rust. Wash regularly — especially through winter and after rain — and remove embedded iron with an iron-removing (iron decon) chemical wash, followed by light non-abrasive clay or a stainless-safe polish for stubborn specks. Never use steel wool, steel brushes or shared shop tools, which re-embed iron, and never leave magnets on the panels. Many owners apply PPF or a ceramic coating to horizontal surfaces to keep contamination from bonding in the first place, which is the only durable prevention on an uncoated panel. Address spots early — surface staining is cosmetic, but iron left embedded can start genuine pitting.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • CitriSurf 77 Stainless-Steel Cleaner and Passivator, 22 oz

    citric-acid removal of embedded free-iron contamination after washing and IPA spot cleaning are ineffective Fitment/availability: Tesla explicitly recommends CitriSurf 77 or equivalent for Cybertruck stainless-panel surface contamination…

    The Rust Store
  • Scotch-Brite Non-Scratch Blue Scrub Sponge, 3 Pack

    specified non-scratch applicator for stubborn contamination during the official citric-acid process Fitment/availability: blue Scotch-Brite non-scratch face matching the tool class named by Tesla; use lightly and only with the official C…

    The Home Depot

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Typical repair cost:$50 - $400

Research This Issue

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

On the 2024-2025 Tesla Cybertruck, the Cybertruck's Power Conversion System is the combined onboard AC charger and high-voltage-to-48V DC-DC converter. On early-build 2024 and some 2025 trucks the unit degrades and fails, typically between roughly 10,000 and 18,000 miles. Owners describe a consistent progression: home charging silently derates from 48A to 24A over a few days, then the truck throws 'AC Charging Unavailable' and refuses to charge on Level 1/Level 2 entirely. DC fast charging at Superchargers usually still works, which is why many owners do not notice until they plug in at home. Because the same module also feeds the 48V low-voltage architecture, a hard PCS failure can cascade into low-voltage faults and in some cases a truck that will not wake. Tesla has been replacing the module case-by-case under warranty rather than issuing a recall, and replacement PCS units have been on national backorder with owners reporting 8-10 week waits. Repeat failures after replacement have been reported.

Common Symptoms

  • AC Charging Unavailable message on center screen
  • Home charging drops from 48A to 24A then stops entirely
  • Cannot charge on Level 1 or Level 2, Supercharging still works
  • Low voltage system fault warnings
  • Vehicle will not wake or respond to app after charging failure

How to Fix

There is no owner-level fix — the PCS is a sealed high-voltage module and replacement is a service-center job (48V and HV hazard). Schedule Tesla service as soon as home charging derates from 48A to 24A rather than waiting for a total failure, because parts are backordered and getting into the queue early matters. Confirm the replacement unit is the revised part number, and re-test sustained 48A AC charging for several sessions after the repair. In the interim, DC fast charging generally still functions. Covered under the basic and HV-component warranties for most affected trucks; document every service visit in case a lemon-law claim becomes necessary.

Typical repair cost:$2,000 - $4,500

Research This Issue

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

On the 2024-2026 Tesla Cybertruck, the motorized retractable tonneau is a slat-and-rail assembly driven along tracks on both bed rails. Three distinct failure modes recur in owner reports: (1) the rail on one side is out of spec or bent, so that side drags and the cover binds — service has ordered replacement tracks; (2) the plastic roller bearings on the slats crack, seize, or fall out of alignment, most often after dusty or off-road driving packs grit into the tracks; (3) the seal slides sideways and bunches up, physically blocking travel. The classic symptom is the cover stopping a few inches short of fully open or fully closed and refusing to go further, sometimes leaving the bed unsecured mid-road-trip. Full mechanism replacement is an 8-hour-plus job requiring special tools and multiple people, and owners report service centers keeping the truck up to two days.

Common Symptoms

  • Tonneau cover stops several inches short of closed or open
  • Cover binds or drags on one side
  • Grinding or clicking from the bed rails while the cover moves
  • Cover will not respond to open/close command
  • Seal visibly bunched inside the track
  • Bed cannot be secured

How to Fix

First run the tonneau Calibrate routine in the service menu on the touchscreen — this resolves a meaningful share of stuck-mid-travel cases, and owners who cycle the cover frequently sometimes need to run it more than once. Then clean the tracks thoroughly: blow out dust and grit and check that the seal has not migrated sideways and bunched. If it still binds, the failure is mechanical — have service inspect the rails for a bent or dragging side and the slat roller bearings for cracks or seizure; track and bearing replacement is covered under the basic warranty on affected trucks. Avoid forcing the cover by hand when it stalls; that is what bends slats and turns a bearing replacement into a full assembly replacement.

Typical repair cost:$500 - $3,500

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026

On the 2024-2026 Tesla Cybertruck, the Cybertruck's adaptive air suspension uses a compressor, valve block, reservoir tank and four air struts. Owners report two related failure patterns. First, air line bundles and strut seals develop leaks; the compressor then runs continuously trying to hold ride height, overheats, and the truck posts 'Air compressor temperature above operating range' followed by 'Air suspension unable to raise' (TAS_a217) or 'Air suspension adjustment unavailable' (TAS_a218). Second, the compressor and valve block fail outright. Symptoms include one corner sagging overnight, the truck refusing to enter Extract or Off-Road ride height, and clunking during low-speed turns. Frequent use of the lift/lower feature and dusty or off-road use accelerate it. Repeat faults after a compressor-only replacement are common because the underlying leak was never found.

Common Symptoms

  • Air suspension unable to raise message
  • Air compressor temperature above operating range warning
  • Air suspension adjustment unavailable
  • One corner of the truck sagging after sitting overnight
  • Compressor audibly running constantly
  • Clunking from suspension during low-speed turns

How to Fix

Do not treat this as a compressor-only job. Have service leak-test the full circuit — strut seals, the air line bundles (which have been found split open), the valve block and the reservoir — before replacing the compressor, otherwise a new compressor will overheat the same way. Successful repairs have typically replaced the valve block plus the compressor, and in leak cases the airline bundle as well. Ride-height calibration must be run afterward so the suspension module relearns each corner's sensor-to-height relationship, or the truck sits unlevel and auto-leveling misbehaves. Let the compressor cool before retrying a raise; repeated retries while hot just re-trip the thermal fault.

Typical repair cost:$800 - $3,000

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Community Reported
High ConfidenceVerifiedReviewed Aug 2026
NHTSA Recalls11 recalls

EXTERIOR LIGHTING

Tesla, Inc. (Tesla) is recalling certain 2024-2026 Cybertruck vehicles operating software prior to 2025.38.3. The vehicle controller software may cause the front parking lights to be too bright and exceed the maximum light output, adversely affecting the vision of other drivers. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, "Lamps, Reflective Devices, and Associated Equipment."

Campaign #25V69900015/10/2025

WHEELS:LUGS/NUTS/BOLTS/STUDS

Tesla, Inc. (Tesla) is recalling certain 2024-2026 Cybertruck vehicles equipped with 18-inch steel wheels. The brake rotor stud holes may crack and allow the stud to separate from the wheel hub.

Campaign #26V25500022/04/2026

STRUCTURE:BODY

Tesla, Inc. (Tesla) is recalling certain 2024-2025 Cybertruck vehicles. The light bar can delaminate and detach from the vehicle.

Campaign #25V17000018/03/2025
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Frequently Asked Questions

What are the most common Tesla Cybertruck problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2025 Tesla Cybertruck has 6 documented issues. The most frequently reported are: Cant Rail Stainless Trim Panel Delamination and Detachment (Recall 25V-170), Power Conversion System (PCS) Failure Kills AC/Home Charging and 48V DC-DC Supply, Off-Road Light Bar Adhesive Failure and Internal Condensation. Of these, 2 are rated critical and should be addressed promptly.

Is the Tesla Cybertruck reliable?

The 2025 Tesla Cybertruck has 6 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: Cant Rail Stainless Trim Panel Delamination and Detachment (Recall 25V-170) and Power Conversion System (PCS) Failure Kills AC/Home Charging and 48V DC-DC Supply. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Tesla Cybertruck problems?

Repair costs for known Tesla Cybertruck issues range from $0 to $4,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Cant Rail Stainless Trim Panel Delamination and Detachment (Recall 25V-170), typically costs $0-$0 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2024-2025 Tesla Cybertruck Cant Rail Stainless Trim Panel Delamination and Detachment (Recall 25V-170)?

The cant rail is the stainless-steel exterior trim panel running along the upper edge of the vehicle between the windshield and the bed. It is bonded to the body with structural adhesive. Tesla determined the adhesive used in production is susceptible to environmental embrittleme… Repairs typically run $0-$0. Severity: high.

What is the 2024-2025 Tesla Cybertruck Power Conversion System (PCS) Failure Kills AC/Home Charging and 48V DC-DC Supply?

The Cybertruck's Power Conversion System is the combined onboard AC charger and high-voltage-to-48V DC-DC converter. On early-build 2024 and some 2025 trucks the unit degrades and fails, typically between roughly 10,000 and 18,000 miles. Owners describe a consistent progression:… Repairs typically run $2,000-$4,500. Severity: high.

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data compiled from NHTSA recalls, manufacturer TSBs, automotive forums, and AI-assisted research. No aggregated owner-report counts available for this vehicle yet.

ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

Tesla, Inc. (Tesla) is recalling certain 2012-2023 Model S, 2016-2024 Model X, 2017-2023 Model 3, 2019-2024 Model Y, and 2024 Cybertruck vehicles. An incorrect font size is displayed on the instrument panel for the Brake, Park, and Antilock Brake System (ABS) warning lights. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 105, "Hydraulic and Electric Brake Systems" and 135, "Light Vehicle Brake Systems."

Campaign #24V05100030/01/2024

VEHICLE SPEED CONTROL:ACCELERATOR PEDAL

Tesla, Inc. (Tesla) is recalling certain 2024 Cybertruck vehicles. The accelerator pedal pad may dislodge and cause the pedal to become trapped by the interior trim.

Campaign #24V27600017/04/2024

+ 6 more recalls. Check all on NHTSA.gov

Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.

What is the 2024-2025 Tesla Cybertruck Off-Road Light Bar Adhesive Failure and Internal Condensation?

The accessory off-road light bar mounted above the windshield was bonded using the wrong adhesive, allowing the bar to loosen and detach from the vehicle and fall into the roadway as a hazard to following traffic; Tesla recalled 6,197 Cybertrucks over it. Separately and persisten… Repairs typically run $0-$0. Severity: medium.

What is the 2024-2026 Tesla Cybertruck Powered Tonneau Cover Jams Mid-Travel from Track, Roller Bearing and Seal Failures?

The motorized retractable tonneau is a slat-and-rail assembly driven along tracks on both bed rails. Three distinct failure modes recur in owner reports: (1) the rail on one side is out of spec or bent, so that side drags and the cover binds — service has ordered replacement trac… Repairs typically run $500-$3,500. Severity: medium.

What is the 2024-2026 Tesla Cybertruck Air Suspension Compressor Overheat and Split Air Lines — 'Air Suspension Unable to Raise' (TAS_a217/TAS_a218)?

The Cybertruck's adaptive air suspension uses a compressor, valve block, reservoir tank and four air struts. Owners report two related failure patterns. First, air line bundles and strut seals develop leaks; the compressor then runs continuously trying to hold ride height, overhe… Repairs typically run $800-$3,000. Severity: medium.

What is the 2024-2026 Tesla Cybertruck Orange Surface Corrosion Spotting on the Stainless Exoskeleton Panels?

Owners began reporting small orange flecks across the stainless body panels within days of delivery — in several documented cases after only a couple of days of driving in rain. The panels are uncoated stainless with no paint or clearcoat, so anything that lands on them stays on… Repairs typically run $50-$400. Severity: low.