Tesla has issued a rare physical recall for one of its vehicles, this time involving more than 6,000 Cybertrucks equipped with an off-road light bar that could detach while driving and create a hazard for other users on the road.
According to the U.S. National Highway Traffic Safety Administration (NHTSA) recall documents, 6,197 model-year 2024 Cybertrucks built at Giga Texas between November 13, 2023, and November 5, 2024 are impacted.
The Issue
Tesla explains that the off-road light bar accessory—manufactured by Hella Romania S.R.L.—was attached to some Cybertrucks with the wrong combination of adhesive primers. Tesla’s investigation found that in certain cases technicians mistakenly applied BetaSeal primer on the windshield and BetaPrime on the light bar itself, instead of the reverse.
The improper bonding could cause partial delamination or complete detachment while driving.
Owners may notice rattling noises inside the cabin, see a visible gap between the light bar and the windshield, or feel the light bar move when touched. Tesla estimates that about 10 percent of the recalled vehicles are affected by the defect.
The Fix
Tesla Service will inspect each vehicle free of charge. If the light bar shows delamination or damage, it will be replaced using adhesive tape and a new mechanical attachment bracket anchored to the vehicle structure. If the bar is intact, technicians will retrofit it with the same bracket system to prevent detachment.
How the Issue Was Discovered
Tesla’s Field Quality team first flagged adhesion irregularities on February 3, 2025, during routine monitoring of repairs. Despite multiple service-manual updates and technician reminders through the spring, additional reports surfaced through the summer, prompting Tesla to launch an engineering study in August.
Chemical analysis completed on October 14, 2025, confirmed the root cause, and Tesla voluntarily initiated the recall six days later. The automaker has documented 619 warranty claims and one field report potentially related to the defect but says it is not aware of any crashes, injuries, or fatalities.
Transport Canada has not yet issued a similar recall. You can read the full NHTSA recall below.
This is the second recall in as many weeks involving a lighting system for the Cybertruck. The other was over the parking lights being too bright, but unlike this Light Bar recall, that one was fixed through an over-the-air (OTA) software update.
