New Tesla Model Y Has Alarming Cracks On Front Casting

Kamel discovered the issue in May, two months after taking delivery of the EV. The owner found the cracked casting while checking whether his car was part of a batch of Model Ys that shipped without a brake fluid reservoir cap. After removing the plastic cover at the windscreen's base, Kamel noticed the lid was there, and so were the cracks.

The giga-casting technique allows the EV maker to hasten production by manufacturing a single aluminum casting instead of multiple elements spot-welded or glued together. But in this case, the cracks could compromise the entire structural integrity of the EV. He even shared a video on YouTube showing that the damages are not just paint cracks.

Could Kamel be at fault? He claims the car wasn't involved in an accident, and the only other explanation is a problem with the original casting method.

That's not how the service technicians view the situation, however. But Kamel is demanding official Tesla documentation to confirm the cracks are not a safety concern.

"The manager of the service center said multiple times that 'the car is safe to drive' and that he had been assured by 'engineers' that it is 'safe.' However, he will not give me anything in more detail or any official Tesla documentation to confirm that," said Kamel. Kamel is warning other Tesla owners driving a modelmanufactured at the Giga Texas检查等问题。

Elon Musk wants to change this negative perception with the Tesla Cybertruck. In a recent internal mail, he demanded sub-10-micron accuracy in the design and manufacturing of all parts.