Tesla has met its recall, which an over-the-air update can’t fix. The company must reserve all 46,096 Cybertrucks built to date after reports that stainless-steel body panels could detach while driving due to faulty adhesive. This raised safety concerns and further complicated the electric pickup’s rocky launch.

The American National Highway Traffic Safety Administration disclosed the recall on Thursday. The body confirms that Tesla will replace the problematic adhesive and reinforce panel structures with welded and riveted supports. 

The recall applies to every Cybertruck produced between the start of commercial assembly and the end of February 2025. Tesla said it became aware of the issue following warranty claims. No accidents or injuries have been reported. Despite its frequent appearances on motor shows, the model is not offered in Europe.

A string of quality issues

Tesla attributed the problem to the environmental degradation of the glue that secures the angular steel trim pieces. Some of these reportedly produced cabin noise before detaching. The automaker plans to begin applying the fix in production, and undelivered trucks will be reworked before reaching customers.

Unlike previous Tesla recalls, many of which have been resolved via over-the-air software updates, this fix requires physical service center visits—a rare move for a brand known for its remote diagnostics. Owners will receive formal recall notices by mail.

The setback is the latest in a string of quality issues plaguing the Cybertruck. A similar recall last year targeted 11,000 units due to other trim failures. The problems already addressed are a loose truck bed panel, a mechanical fault that risked power loss to the wheels, and a conflicting accelerator that could get stuck. Also, a full recall was deployed for the latter.

Cheaper version to the rescue

Despite marketing the truck as rugged and even bulletproof, this recall spotlights Tesla’s manufacturing inconsistencies and quality problems, which the young company has been wrestling with since the start.

Moreover, the bad news comes from stalling Cybertruck sales while the vehicle’s depreciation is peaking at a 58% loss—the biggest of all Tesla models. 

The EV maker revealed for the first time that it has delivered 46,000 Cybertrucks since launch. However, based on estimates, it’s expected to provide only 7,000 to 8,000 units in the first quarter of this year, a sharp drop pointing to the model’s real potential after the early adopter enthusiasm has withered. This dip comes despite added buyer incentives, including a $7,500 EV tax credit, discounted financing, and free Supercharging.

Near-term viability

The delivery slowdown is raising doubts about the Cybertruck’s near-term viability. Analysts claim only the delayed, lower-cost rear-wheel-drive version could broaden appeal later this year. Compounding the challenges, Tesla is preparing to overhaul the Cybertruck’s battery technology to cut costs.

The company wants to introduce dry cathode versions of its 4680 battery cells later this year. According to Tesla, these cells, which eliminate liquid solvents in the cathode manufacturing process, could trim production costs by up to $1 billion.