Tesla has voluntarily recalled 6,197 Cybertrucks because an incorrect primer may cause the optional off-road lightbar to detach from the windshield. The issue affects vehicles with the dealer-installed lightbar, potentially turning it into a projectile for nearby traffic. Owners will receive fix instructions via mail in late December.
Late last month, Tesla initiated a voluntary recall of 6,197 Cybertrucks, impacting about 10 percent of the vehicles on the road. The problem involves the optional dealer-installed lightbar, designed to enhance visibility during off-road use after sunset. According to the National Highway Traffic Safety Administration (NHTSA), Tesla used an incorrect surface primer when gluing the lightbar to the top of the windshield, with no fasteners employed for attachment. This error increases the risk of the lightbar detaching and becoming a hazard to drivers and pedestrians in the vicinity.
The Cybertruck, marketed as a capable off-roader equipped with electronic locking differentials and various off-road modes, offers the lightbar as an accessory. Although it may not surpass competitors like the Ford F-150 Raptor or Ram TRX in rugged performance, the lightbar aims to improve nighttime operations. Tesla's service manual details the preparation process, where primer is applied to the lightbar's underside for better adhesion, similar to how purple primer cleans and softens materials in PVC joint applications before cement bonds them.
To address the issue, Tesla Service will inspect each affected lightbar and install an additional mechanical attachment. If necessary, the lightbar will be replaced using tape for adhesion along with the extra mechanical fix, all provided free of charge. NHTSA reports that owner notification letters will be mailed on December 26, 2025. Service appointment availability remains unclear, potentially delayed by months based on prior Cybertruck glue-related recalls.