Elon Musk’s audaciously styled and self-proclaimed “apocalypse-proof” Cybertruck has encountered yet another unexpected obstacle in its ongoing journey toward mass acceptance and reliability. Tesla, the automaker renowned both for its innovation and for the controversies that often accompany its products, has issued a new recall affecting as many as 6,197 Cybertrucks. According to a regulatory notice submitted on Monday, the manufacturer inadvertently used an inappropriate adhesive to secure the vehicle’s optional off-road light bar—an error that has now raised legitimate safety concerns. The affected component, which sits prominently above the truck’s expansive, sloped windshield, plays both an aesthetic and functional role: it is designed to illuminate distances of up to approximately 525 yards, assisting drivers in dark, rugged terrain. However, the use of the wrong bonding material could result in the light bar dislodging during operation. The National Highway Traffic Safety Administration (NHTSA), in its official recall documentation, warned that such detachment could transform the component into a dangerous road hazard capable of endangering other motorists.
Tesla began offering this specific accessory late last year as part of the “Cyberbeast”—a high-performance trim level of the angular, stainless steel-bodied pickup. Owners who opted for this enhancement sometimes faced an unconventional installation process. Several purchasers were advised that final attachment and activation of the LED light system were their personal responsibility—a rather unorthodox approach in the modern automotive industry, where factory or dealer installation is the norm. According to Tesla’s own service manual, company technicians are legally prohibited from installing or activating the light bar’s electronic systems. Instead, the documentation stipulates that the component must be provided to the customer under blackout film tape, which only the owner is authorized to remove. This seemingly minor procedural quirk now lies at the center of the recall, illustrating how Tesla’s blend of futuristic design and regulatory complexity can occasionally produce unforeseen complications.
In its official report, Tesla stated that it currently has no evidence of any accidents, injuries, or fatalities related to the defective adhesive. Nevertheless, the company opted to act preemptively. Affected customers will receive replacements for their potentially faulty light bars, each newly secured with a more robust attachment system—a combination of enhanced adhesive tape and a firmly engineered mechanical fastener. Tesla emphasized that this corrective measure will be provided completely free of charge, as part of its standard recall policy.
This latest issue follows several weeks of anecdotal reports from Cybertruck owners who had taken to social media platforms and online automotive forums to express frustration after witnessing their light bars detach while driving. Such incidents, though seemingly isolated, generated swift attention due to the vehicle’s high profile and Tesla’s reputation for cutting-edge but occasionally imperfect production runs. The company, in characteristic fashion, declined to provide direct comment in response to inquiries regarding the current recall.
The recall represents yet another entry in the growing list of quality-control challenges facing the Cybertruck since its highly publicized launch in November 2023. While some mechanical and software anomalies have been conveniently corrected through Tesla’s celebrated over-the-air update system—a hallmark of the brand’s technological prowess—other defects have necessitated traditional, physical interventions at service centers. Earlier in the year, for instance, Tesla recalled approximately 46,000 Cybertrucks after identifying that an exterior trim panel could detach while in motion, prompting fears of additional safety hazards. Soon after, in April, about 4,000 of the futuristic trucks were recalled due to a malfunction that risked causing the accelerator pedal to jam, potentially increasing the likelihood of loss of control.
Elon Musk once publicly projected that Tesla’s production lines could scale up to manufacture as many as 250,000 Cybertrucks annually, a target intended to demonstrate both the company’s manufacturing might and the vehicle’s mass-market viability. Reality, however, has proven more challenging. Recent data from Cox Automotive indicates that Tesla has sold approximately 16,000 Cybertrucks during the first nine months of the year. Alarmingly, the third quarter alone saw a 62.6 percent decline in year-over-year sales, suggesting that enthusiasm for the trapezoid-shaped, stainless-steel pickup may be wavering amid reports of mechanical defects, logistical delays, and consumer hesitation.
Altogether, the current recall reinforces a pattern that many industry observers have come to associate with Tesla’s rapid innovation cycles: bold, boundary-pushing designs often accompanied by equally dramatic growing pains. As the company works to refine its Cybertruck into the rugged, future-ready vehicle Musk once promised, this episode serves as another reminder that even the most technologically advanced automaker is not immune to the meticulous demands of safety compliance and material precision.
Sourse: https://www.businessinsider.com/tesla-recalls-cybertrucks-light-bar-fly-off-glue-2025-10
