Tesla has issued its tenth recall for the Cybertruck, affecting 6,197 Foundation Series models from 2024 due to an optional off-road LED lightbar that may detach from the windshield. The issue stems from improper adhesive installation at service centers, leading to over 600 warranty claims. No crashes, injuries, or fatalities have been reported.
Tesla announced a recall on October 31, 2025, for 6,197 2024 Cybertruck Foundation Series vehicles equipped with an optional off-road LED lightbar. This marks the tenth recall for the electric pickup since deliveries began in late 2023. The lightbar, installed exclusively at Tesla service centers, is attached to the windshield using adhesive rather than mounting hardware. According to National Highway Traffic Safety Administration (NHTSA) documents, the problem arises from service technicians failing to follow updated installation instructions, specifically regarding the use of two primers: BetaPrime for the windshield and BetaSeal for the lightbar itself.
The first instances of detaching lightbars were reported in February 2025. Tesla updated the guidelines earlier that year to clarify primer application, but some technicians continued using the wrong products. This has resulted in 619 warranty claims and one field report related to delamination. A detaching lightbar could pose a road hazard, increasing crash risk, though Tesla states it is unaware of any related collisions, injuries, or deaths.
To address the issue, Tesla will perform free inspections at service centers. Vehicles showing delamination or damage will receive a replacement lightbar installed with adhesive tape and a positive mechanical attachment. Undamaged units will be retrofitted with a mechanically anchored bracket, plus adhesive tape if needed. Owner notification letters are scheduled to be mailed on December 26, 2025. The recall code is SB-25-90-001, and affected vehicles were built between November 2023 and November 2024.
This recall follows a recent one for over 63,000 Cybertrucks involving overly bright parking lights, resolved via over-the-air update. Adhesive bonding is a standard practice in the auto industry for structural components, but proper installation is critical.
