Tesla Recalls 6,197 Cybertrucks Over Detaching Off-Road Lightbars
Tesla has recalled 6,197 Cybertruck vehicles equipped with dealer-installed off-road lightbars due to improper surface primer that increases the risk of detachment during operation. The National Highway Traffic Safety Administration reported that the lightbar, mounted above the windshield, could become a road hazard if it falls off, potentially endangering other drivers. This marks the third recall for the Cybertruck in 2025, following earlier fixes for accelerator pedal issues and stainless steel trim panels.
The affected lightbars, part number 2009846-00-A, were installed on 2024 and 2025 model-year Cybertrucks produced from November 13, 2023, through November 13, 2025. Tesla’s investigation identified that inadequate primer application on the mounting surface leads to insufficient adhesion, exacerbated by environmental exposure. Owner notification letters will be mailed on December 26, 2025, with service centers scheduled to inspect and reinforce or replace the units at no cost. The remedy involves adding a mechanical attachment or applying tape alongside a new bracket.
Cybertruck production at Gigafactory Texas totals approximately 60,000 units since late 2023, making this recall impact about 10 percent of the fleet. Tesla’s service network, expanded to 500 locations nationwide, aims to complete fixes within 60 days, though prior recalls averaged 90-day resolution times. The lightbar option, priced at $2,975, enhances low-light visibility for off-road use but requires careful installation per federal motor vehicle safety standards. No crashes or injuries have been reported from this defect.
This recall coincides with Tesla’s Q4 2025 delivery surge of 497,000 vehicles, including 12,000 Cybertrucks, amid softening overall EV demand post-federal tax credit expiration. BloombergNEF data shows U.S. EV sales dipped to 6 percent market share in November 2025, down from 12.9 percent in September. Tesla’s free-charge incentives and software updates have sustained Cybertruck interest, with wait times now at four months for Foundation Series models. The company attributes the primer issue to a supplier variance resolved in October 2025 production runs.
NHTSA’s probe, initiated November 15, 2025, reviewed 152 consumer complaints and Tesla’s internal telemetry from 1,200 affected vehicles. Agency spokesperson Adrienne Brown noted, “Detaching accessories pose immediate risks on highways, where Cybertrucks average 65 miles per hour.” Tesla’s over-the-air diagnostics flagged 18 percent of units with early adhesion failure during vibration tests simulating 10,000 miles of mixed terrain. Owners can verify status via VIN lookup on nhtsa.gov, with interim guidance to avoid high-speed travel until serviced.
The Cybertruck’s stainless steel exoskeleton, designed for durability, has faced scrutiny in prior recalls, including a March 2025 action on 46,096 units for loose cant rail panels affecting 1 percent of the build. Insurance Institute for Highway Safety tests rate the Cybertruck five stars overall but highlight accessory integration vulnerabilities. As Tesla ramps Optimus robotaxi production for 2026, reliability metrics like these influence fleet adoption by rideshare operators. This development tests consumer confidence in the $80,000-plus electric pickup amid competitive pressure from Ford’s F-150 Lightning, which sold 24,000 units in Q4.
