Tesla has recalled 6,197 Cybertrucks in the United States because the optional off-road LED light bars may detach while driving, posing a road hazard. The issue stems from incorrect adhesive application during assembly. No crashes or injuries have been reported.
The recall affects certain 2024 Tesla Cybertruck models, primarily the high-performance Cyberbeast variant, manufactured at the Texas Gigafactory between November 13, 2023, and November 5, 2024. According to documents filed with the U.S. National Highway Traffic Safety Administration (NHTSA), the problem involves the use of an incorrect surface priming material on the windshield and the light bar accessory. Tesla stated, “Despite service instructions specifying use of the correct primer for each surface, in some cases, service technicians were inadvertently using BetaSeal on the windshield and BetaPrime on the optional off-road light bar accessory.”
Tesla has identified 619 warranty claims and one field report related to the issue as of October 24, 2025. The light bars, available as a factory option or added through Tesla service, could detach due to vibrations while driving. This marks the 10th recall for the Cybertruck since its launch in late 2023.
To address the defect, Tesla's service department will inspect the light bars and either install an additional mechanical attachment or replace the light bar using tape to adhere it to the windshield along with a mechanical attachment, all free of charge. Owners will receive notification letters by mail on December 26, 2025, and may contact Tesla customer service at 877-798-3752. The recall number is SB-25-90-001. Owners can check if their vehicle is affected by entering the VIN on Tesla's recall search page or the NHTSA website.
The recall highlights ongoing production challenges for the Cybertruck, which has faced multiple quality issues since its debut. While the light bar defect has not been linked to any accidents, it underscores concerns about assembly processes at Tesla.
