Tesla has introduced a new bolt-on bracketing system to address a recall affecting over 6,000 Cybertrucks, where the off-road lightbar could detach due to faulty adhesive. The fix, detailed in service bulletin SB-25-90-001, adds physical anchors to the vehicle's roof frame. No accidents or injuries have been reported from the issue.
In October 2025, Tesla and the National Highway Traffic Safety Administration recalled 6,197 Cybertrucks equipped with the off-road lightbar accessory. The problem stemmed from an incorrect surface primer supplied by Hella Romania S.R.L., which caused the urethane adhesive to fail, potentially allowing the lightbar to detach while driving and pose a road hazard.
The new remedy replaces reliance on adhesive with a mechanical attachment. According to the service bulletin SB-25-90-001, technicians install brackets that bolt the lightbar directly to the vehicle's frame. This involves drilling a hole through the cosmetic roof appliques and into the roof frame, then sealing it with a threaded rivet nut to secure the bracket. Tesla notes that this method ensures the lightbar stays attached even if the adhesive completely fails, unlike third-party lightbars that might use rooftop rack mounts.
The installation process varies by the lightbar's condition. If it is firmly attached, service teams add the brackets without removal, serving as a safety retention system. For loose lightbars, the unit is fully removed, old adhesive is cleaned, and it is reinstalled using high-strength VHB tape before adding the brackets. Future installations will standardly combine VHB tape for flush mounting with the bolted brackets for security.
Repairs are free for affected owners and can be performed by mobile service technicians in a few hours, provided there is no delamination or damage. This marks the third Cybertruck recall in 2025, following issues with exterior trim panels and overly bright front parking lights.