Suspension Noise Problems of Tesla Model 3

Both front tires on my 2024 Tesla Model 3 performance developed structural bulges on the inboard sidewall at under 19,000 miles. The tires are the original equipment pirelli p zero 235/35r20 delivered with the vehicle on 12/07/2024. On 08/05/2026 at 18,951 miles, Tesla service in doral, florida inspected and road-tested the vehicle for a metallic rubbing noise that increases with speed and also occurs at low speed at full steering lock under acceleration. Tesla's own repair notes on invoice 3000s0017877728 state that the noise was duplicated on the road test and appears to originate from deformed front tires. Tesla took no alignment measurement and the invoice contains no camber, caster or toe readings. The same invoice records tire pressures of 40. 2, 39. 9, 40. 6 and 39. 9 psi, so underinflation is not a factor. The failures are symmetric: same axle, same inboard face, both sides, at the same time, which is not consistent with isolated independent road hazard impacts. The bulges are on the inner face and are not visible during a normal walk-around inspection. Tesla states it provides no warranty coverage for tires and declined any vehicle-side diagnosis. A sidewall bulge is a sudden blowout risk, and two of them on the steering axle of a high performance vehicle capable of highway speed is a safety defect concern. Other Tesla owners have reported the same inboard sidewall bulge pattern at low mileage on 20-inch wheels, some as early as 7,000 miles. I request that NHTSA review whether front suspension geometry or the tire and wheel package on this vehicle contributes to premature inboard sidewall failure. The vehicle remains under its 4-year/50,000-mile basic vehicle limited warranty.

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The front control arm is damaged, interestingly about 6 months after the warranty has expired. Tesla repair tech tells me its so common that they don't charge for the repair but do charge for the part. As I sit in the Tesla repair centre waiting for it to be fixed, 3 other people with exactly the same problem just walked in describing exactly the same problem. I don't understand what this part does but given it's part of the suspension, it poses a safety risk. There were no warnings except for a very loud squeaking noise every time the car turns or encounters a bump.

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Here is another Tesla Model 3 in the junkyard. The front suspension has fallen to bits. All 3 ball-joints have simply popped apart. Even in cars that have been in major crashes it is unusual to see a ball joint that has separated. There are many reports on the forums that the ball joints on Model 3 cars are squeaking badly when the steering is turned side to side. Example: https://teslamotorsclub. Com/tmc/threads/time-to-replace-upper-control-arm-ball-joints. 202921/page-3 time to replace upper-control arm ball joints | page 3 | Tesla . . . Teslamotorsclub. Com ' Tesla: vehicles ' Model 3 I am exceptionally disappointed that Tesla will not honor what's clearly a fleetwide part failure issue for the ball joints ** owners are resorting to diy repairs by injecting grease or wd40 through the rubber boot. The squeaking sound means that metal is rubbing on metal. Eventually the ball wears down sufficiently for it to pop out of its socket. I have made reports to you already on this subject and have supplied many photographs of Tesla popped ball joints. I strongly urge you to take immediate action by issuing a recall. Thank you. Keef.

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Friday June 26th, 6:00 p. M. Public roads. Sunny, dry. Something snapped while driving 5 mph at the moment I started a slow left turn. The car lurched to a halt. The right front wheel was angled left at about a 35 degrees, while the left wheel pointed straight. Tesla sent a flat bed. The truck technician reported by phone that the wheel was separated from the suspension and a Tesla bolt was available for him to temporarily hold alignment for safe loading. I understand he left a note and the bolt inside the car. I believe the bolt was part of the broken suspension. The car had 3,300 miles. During my ownership, I noticed a light clicking (or clunking) when the car passed over a 3 inch change in road elevation, such as occurs during repaving when striking a man hole cover or new layer of asphalt. I took this to be a peculiarity of the Tesla suspension combined with the 18 inch wheels. The sound was rare, as most roads are quite smooth and I made it a point to drive slowly over sudden bumps. More recently, as our town is repaving, I heard the click more frequently. On father's day, while a friend was test driving the car, he being a car geek, heard the click, called it a "clunk," and told me to get it looked at. I had not yet made the appointment when something snapped on June 26th. Over the weekend I left voice mails and sent to Tesla service an email stating Tesla should consider giving me a replacement vehicle, but I wished first to hear their report on what had occurred. Tesla service in milford is not open on weekends. Tesla called on Monday afternoon seeking my input on what had occurred. Later that day they reported it appeared to them that a critical bolt had not been welded onto the sub-frame. Tesla service in milford ordered a new sub-frame, part number 1044521-00-r, from California. Tesla is researching what occurred.