2013 Tesla Model S suspension problems

“I own a 2013 Tesla Model S. While investigating a knocking noise from the rear of the vehicle, I had a local shop disassemble the affected area and we discovered a crack in the rear subframe near a weld and mounting bracket. The fracture appears clean, with little or no visible corrosion. No previous repairs have been performed in the affected area. Given the location of the failure and the structural function of the component, I request an engineering review to determine the likely failure mechanism and whether similar failures have been documented on early Model S vehicles. My research shows the same failure in NHTSA complaint XXX. Other local shops also describe the same subframe failure on this Model and manufacturing year. Please advise whether any applicable service campaigns, revised replacement components, or goodwill repair assistance are available. I am attaching photographs. My vehicle VIN is [XXX].”

“Driver's side rear control arm failure. The outside knuckle of the control arm cracked and is missing a portion. Tesla agrees this is SB-19-31-001 and will not repair without payment, due to the age of the vehicle. Vehicle has been serviced by Tesla multiple times without comment that this should be replaced.”

“When driving my vehicle the rear axle snapped causing the vehicle to fishtail. When checked by insurance company for repairs they found the Air suspension and rear axle snapped. It took out the air ride suspension, and bent 2 rims. It caused damage to the front fender as well as both interior wheel wells on the driver's side. Due to the suspension issue it caused a rock to come up and cracked windshield. The issue caused my vehicle to leave the road as I could not control the vehicle.”

“Lower rear driver side control arm broke. A pop was heard at the stop sign only yards away (40 approximately) from my destination. Vehicle was placed into reverse to back into a driveway. The vehicle got stuck in the middle of the road and required a tow to move it.”

“I bought a used, but well cared for, gently used and properly maintained, 2013 Model S P85 from an individual in CT on Oct 8, 2022 with 77937 miles on it. I had the car about a month and a half of normal use when it ran well with zero issues, which included driving all the way from NY to VT over Thanksgiving at highway speeds with no issue. When back in my own town and making just a few turns to get to work on local roads on 11/28/22, I found myself losing control of the steering column and going off the road at a very low speed. The only indication that something was wrong was the traction light that came on just before I couldn't steer anymore and luckily found my way off to a soft shoulder. The front right tire was tilted in significantly and the car required a tow, and then a whole series of expensive and extensive repairs effectively replacing all components of a failed suspension system, starting with a broken control arm on that front left side. The incident left me shaken. Even when I get my car back, assuming I can find a way to pay for this (currently $4K+), I am now not very confidant in the new but insufficient suspension parts, learning that so…”

“Component failed: Rear subframe cracked Safety risk: Car not stable to drive at speed, drive unit can twist or flop/drop Confirmed issue w/ dealer who is also manufacturer. Root cause of failure not established, but no signs of collision. Working hypothesis is metal fatigue or stress as metal part is not built thick enough to withstand force places on it causing shearing. There are no warning lights or lamps, no symptoms prior to failure.”