Another Tesla Safety Probe – and This One Could force the Recall of 1.2 Million EVs

Tesla has been facing some significant safety challenges this year and federal regulators are adding to its woes with a probe into reports of suspension issues that could lead to the recall of as many as 1.2 million of its EVs. This follows the recall of some Tesla Cybertrucks whose wheels quite literally could fall off. More from Headlight.News.

Tesla faces the prospect that nearly 1.2 million of its best-selling EVs could be recalled due to reports of suspension failures that could occur unexpectedly and leave drivers unable to recall their vehicles.

The National Highway Traffic Safety Administration has launched what it describes as a “preliminary evaluation of the problem which covers Model 3 sedans built between 2018 and 2020, as well as 2021 through 2023 Model Y crossovers.

Tesla previously recalled a small number of the Model 3 line to deal with a lateral link problem but the new investigation covers significantly more vehicles. And it comes at a time when Tesla has been coming under close scrutiny for other safety issues, including the recall of some Cybertrucks in May because of concerns their wheels could fall off.

What’s new

The latest investigation covers 1,198,300 Tesla battery-electric vehicle and it follows 156 complaints filed with the agency – though there so far have been no reports of crashes, injuries or fatalities.

At the center of the investigation: the suspension’s front lateral link which according to reports, can unexpectedly detach. In such an event a driver would immediately lose control of the vehicle. According to the reports received by NHTSA, those who’ve experienced the problem received little to no warning – at most some “odd” noises immediately before the suspension came apart.

Despite the relatively large number of reports, however, federal regulators are just beginning to look into the problem and it is far from certain there will be a recall.

Growing list of safety issues

Tesla previously experienced problems with the suspension on a smaller number of Model 3s – and it’s not clear if the latest issue involves the same problem.

Experts are advising motorists to have a mechanic check out any of the EVs covered by the probe for signs of unexpected suspension wear or indications of a potential failure.

Tesla has not indicated how it is handling the situation when a failure does occur. Should the reports lead to an eventual recall repairs would be made at no cost to owners. It’s also unclear whether those who’ve already had suspension issues would be reimbursed for any prior expenses.

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Mounting problems

The suspension probe is just the latest in a series of safety-related problems involving the Texas-based Tesla. Among the most notable recent incidents:

• Some base versions of the Tesla Cybertruck were recalled because the 2024-2026 models equipped with 18-inch steel wheels could have those wheels crack and then fall off;
• A month earlier, over 218,000 Tesla Models S, X, 3 and Y were recalled because of problems with their rearview cameras;
• About 13,000 Tesla EVs were recalled due to faulty “battery contactors” that could cause a sudden loss of power were they to fail.

Over the last 12 months Tesla has also ordered recalls due to exterior lighting defects, problems with the electrical propulsion system and other wiring issues.

If there’s good news for Tesla it’s the fact that its sales rebounded strongly during the second quarter of 2026, at 480,126 worldwide. That handily exceeded Wall Street expectations. The increase came despite the end of production for the older Models S and X and largely reflected a revival of demand in Europe.