2020 Tesla Model 3 Suspension Problems

Vehicle made thunking noise when driving over uneven surfaces such as bumpy roads, speed bumps, or railroad tracks. Diagnosis at Tesla service center showed front upper control arms assemblies (left and right), lower lateral link, and front lower compliance link (left and right) required replacement. Of note: upper control arm assemblies were previously replaced under warranty in November 2021 at 28000 miles. This short interval indicates defective suspension components leading to cascading failures putting driver safety at risk.

The front suspension control arms on my 2020 Tesla Model 3 are squeaking and show premature wear. The noise occurs during normal driving and is accompanied by clunking, which concerns me about potential control arm failure and loss of vehicle control. My vehicle is only 40k miles and it’s a very common issue that Tesla gets to make money on. Kind of funny it happens to everyone right when the warranty ends. I am aware that this is a known issue affecting multiple Model 3 vehicles. Despite proper maintenance, the problem persists and may present a safety risk. I request that this be officially recorded as a safety complaint.

I am writing to formally report a critical safety incident involving my 2020 Tesla Model 3, where the bumper detached while driving through a puddle of water on Oct 9th, 2025. This occurred on a busy street, and fortunately, another driver alerted me just in time, averting a potentially serious accident. Following the incident, I arranged for my vehicle to be towed to a Tesla-authorized collision center and opened a claim with my insurance company. I have since learned that this issue is recognized internally by Tesla, as they have created a service incident regarding it, but have failed to communicate this to customers effectively. Tesla's lack of accountability is concerning. Despite repeated attempts to address this with their support and service teams, they have deflected responsibility and continue to downplay the seriousness of this matter, insisting I must rely on insurance to cover the costs. This situation raises significant safety concerns, not just for myself but for all Tesla Model 3 drivers. I urge NHTSA to take the following actions: 1. Investigate this safety issue regarding the bumper detachment on Tesla Model 3 vehicles. 2. Pressure Tesla to publicly acknowledge this known issue and take immediate corrective action to prevent future occurrences. 3. Ensure that affected customers are compensated for damages and repairs due to this defect. I appreciate your attention to this serious safety issue and look forward to seeing NHTSA hold Tesla accountable to protect all consumers and ensure vehicle safety. I have attached proof of diligent efforts on my part to get this resolved: - Claim number with Progressive - Communication with Tesla giving them proof of this issue - Earlier NHTSA bulletin acknowledging the issue and the Tesla internal service incident created for this issue. Thank you for your urgent attention to this matter.

Front lower and upper control arms started generating noise around 100,000 miles. This was confirmed by an independent service center. So far, have spent $1400 on the lower control arms, only to find out that the noise is still there and the upper control arms need to be replaced as well.

The front suspension is failing. I have already replaced the upper control arms. Now I need to replace the bushings on compliance and lateral linksare tearing. There have been recalls for this model and year, for this issue. My VIN, is not included in the recall. I was notified of the aditional needed repairs when I had the upper control arms replaced.

I am experiencing persistent front suspension issues with my Tesla Model 3 Performance. The vehicle has been taken to a Tesla Service Center three times, yet the problem has not been resolved. The issue includes: Unusual noises (clunking, knocking, or creaking) from the front suspension. Instability or poor handling at various speeds. Repeated failures of suspension components despite repairs. Each time, Tesla service has attempted repairs, but the issue continues to persist, raising serious concerns about the safety and durability of the suspension system.The vehicle is currently at Tesla service center as of March 4th 2025 and they are working on the same problem for the 3rd time.

THE FRONT CONTROL ARM IS DAMAGED, INTERESTINGLY ABOUT 6 MONTHS AFTER THE WARRANTY HAS EXPIRED. TESLA REPAIR TECH TELLS ME ITS SO COMMON THAT THEY DON'T CHARGE FOR THE REPAIR BUT DO CHARGE FOR THE PART. AS I SIT IN THE TESLA REPAIR CENTRE WAITING FOR IT TO BE FIXED, 3 OTHER PEOPLE WITH EXACTLY THE SAME PROBLEM JUST WALKED IN DESCRIBING EXACTLY THE SAME PROBLEM. I DON'T UNDERSTAND WHAT THIS PART DOES BUT GIVEN IT'S PART OF THE SUSPENSION, IT POSES A SAFETY RISK. THERE WERE NO WARNINGS EXCEPT FOR A VERY LOUD SQUEAKING NOISE EVERY TIME THE CAR TURNS OR ENCOUNTERS A BUMP

upper control arm is creaking, extremely common problem, we need to demand a recall

I am writing to express my concern regarding the recurring issue with the control arms and sway bar in the 2020 Tesla Model 3. It has come to my attention that Tesla acknowledges this issue, which manifests as creaking sounds during various driving conditions such as climbing into the car, traveling at low speeds, and navigating over speed bumps or uneven terrain. What's particularly troubling is that when I brought my car into them Tesla acknowledged that they are aware of the prevalence of this issue across many of their vehicles, yet they continue to charge consumers for repairs, even if their vehicle is not included in the recalled VINs. This policy unfairly burdens consumers who experience the same issue but are denied coverage under the recall. I urge the NHTSA to investigate this matter thoroughly to ensure consumer protection and fairness in addressing safety concerns in Tesla vehicles. It's essential that manufacturers uphold their responsibility to rectify known issues without imposing undue financial burdens on consumers.

My vehicle is 4 years old. 3 weeks after the expiration of my original warranty, the front suspension now squeaks loudly when driving at low speeds. This issue matches the known manufacturing defect described in Tesla’s 2021 service bulletin, “Reseal Front Upper Control Arm Ball Joints.” We never received this bulletin from Tesla, and we were never given the option of resealing the joints. As a consequence, the ball joints have now failed and both upper control arms must be replaced, at a cost to me of $330. I asked if Tesla can waive these repair costs due to the bulletin and widespread manufacturing defect, but Tesla declined, stating: “Your vehicle is not listed as an affected VIN for this bulletin. In order for a repair bulletin to be covered under the vehicle warranty the condition has to be reported within the warranty period. Once no longer under warranty, it is not covered.” Even though my VIN was not included, clearly it should have been since the ball joints have failed. Also, if this is a known car defect, why should it matter when the problem starts to appear in order for Tesla to take full responsibility and fix it? They are shifting costs to consumers for their own, known, widespread manufacturing defects. Additionally, if I had been informed about the bulletin in 2021, resealing the joints at that time would have been easier & far cheaper than replacing both arms now. It’s my understanding that Senators Markey (MA) and Blumenthal (CT) expressed concern that this defect could be a safety risk, and urged Tesla to issue a voluntary recall, which Tesla declined. I hope NHTSA will consider investigating this manufacturing defect further. Thank you very much for your time. Vehicle is available for inspection. Yes, an independent service center confirmed this suspension problem. A Tesla repair service center will inspect the components on [XXX]. No, there were no warning lamps, messages or symptoms prior to failure. The failure began on [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Car has 39,445 miles on it. Groaning noise started in front tires. Took it in for inspection and Tesla replaced the upper control arm and lower lateral link for both the front left and front right tires. I see that there was a recall for these parts in many Tesla 3, including my model year but my VIN didn’t qualify. Seems coincidental that I would have an issue with the same part that was recalled at only 40k miles but not under the recall.

Driving the vehicle will start doing several noises in the front and back suspension. It’s very stressful to hear that kind of noise besides that people isn’t really sure it suspension going to fail at some point which potentially could be really dangerous. Tesla has recall this kind of issues outside the us but refuses to do a recall in the us where the have most of their cars risking the roads. added to that they should’ve included a spare tire kit on their cars.

The contact owns a 2020 Tesla Model 3. The contact stated while driving approximately 40 MPH, the vehicle rolled over an uneven road surface and the contact heard an abnormal creaking and squeaking sound coming from the front driver’s side wheel well. The contact stated no warning light was illuminated. The contact stated that the failure was intermittent at first but had become a recurring failure at various speeds. The contact stated that the sound had become much louder. The contact had taken the vehicle to a dealer, where it was diagnosed and determined that the driver’s and passenger’s side front upper control arms and lower links needed to be replaced due the seals deteriorating and disintegrating. The vehicle had not been repaired. The manufacturer had been informed of the failure. The failure mileage was 59,135.

The upper control arm on my vehicle creaks and it is a known issue amongst the Tesla model 3 owners. This creak can eventually wear to the point the ball joint will separate during driving. This is a safety issue that can cause an accident. Tesla denied the warranty repair due to some after market parts. This is not a valid reason to deny me warranty because this issue is prominent in all cars of this model and year regardless of aftermarket parts or not. Currently the issue is present at low speeds. Tesla applied a "patch" to keep water from getting into their poorly designed ball joint. Unfortunately by the time they got to this repair for my vehicle it was too late. And water had gotten in and caused the damage and now it is a safety concern.

Driving home at 60mph when the right front wheel fell off the vehicle causing damages to the whole right side on the car.

HERE IS A 2020 TESLA MODEL 3 IN THE JUNKYARD. HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/39123018?TENANT=US&ROWNUMBER=1 THE FRONT SUSPENSION HAS FALLEN TO BITS. THE WHEEL IS DISPLACED BACKWARD SO THAT THE TIRE IS RUBBING AGAINST THE FRAME AND THE BATTERY. THE TREAD ON THAT TIRE IS WORN AWAY WHICH IS AN INDICATION THAT IT WAS RUBBING AGAINST THE FRAME WHILE THE CAR WAS STILL DRIVING AND BEFORE THE WHOLE SHEMOZZLE TURNED TO FECULENCE. THIS IS NOT GOOD. THIS IS NOT GOOD AT ALL. IF IT IS NOT TOO MUCH BOTHER FOR YOU WOULD YOU MAKE INQUIRIES INTO WHY TESLA CHOOSES TO MAKE SUSPENSION COMPONENTS OUT OF CHEESE. THANK YOU. KEEF

THIS IS MIND BOGGLING! HERE IS A 2020 MODEL 3 TESLA IN THE JUNKYARD. HTTPS://WWW.IAAI.COM/VEHICLEDETAILS/37712955?ROWNUMBER=3 IT HAS NOT BEEN IN A COLLISION, NO AIR-BAGS HAVE DEPLOYED AND THERE IS NO SIGN OF ANY IMPACT TO THE BODYWORK. THE FRONT SUSPENSION HAS SIMPLY FALLEN TO BITS. ALL THE BALL-JOINTS HAVE POPPED APART AND EVEN THE STEERING KNUCKLE HAS SNAPPED IN HALF. AND MUSK CLAIMS THAT THIS IS THE SAFEST CAR IN THE WORLD! PIGS BOTTOM! HAVE A GREAT DAY AND BE SURE TO BAN THESE JUNKHEAPS FROM THE HIGHWAYS. THANKS KEEF

HERE IS A TESLA MODEL 3 IN THE JUNKYARD. HTTPS://WWW.COPART.COM/LOT/35210670/PHOTOS/2020-TESLA-MODEL-3-NJ-SOMERVILLE IT HAS TRAVELLED JUST 200 MILES SINCE LEAVING THE TESLA TENT. IT IS LISTED AS HAVING SUSPENSION DAMAGE. THE FRONT OF THE CAR HAS DROPPED SO FAR THAT THE WHEELS ARE JAMMED UP IN THE WELLS. IT IS INSANE AND LUDICROUS THAT THESE CARS DO NOT HAVE LIMIT STOPS ON THE AIR SUSPENSION SO THAT A SIMPLE AIR-LEAK DOES NOT LEAD TO A DISASTROUS COLLAPSE. IN THIS INSTANCE THERE WAS NOT A MAJOR CRASH BUT THAT IS ENTIRELY DOWN TO LUCK. I HOW MANY DEAD AND MANGLED PEOPLE DO YOU NEED BEFORE YOU GROUND THESE DEATH-TRAPS? YOURS IN DISGUST KEEF

YET ANOTHER TESLA MODEL 3 IN THE JUNKYARD WITH A POPPED OUT BALL JOINT. HTTPS://WWW.COPART.COM/LOT/42415580/PHOTOS/2020-TESLA-MODEL-3-NJ-TRENTON THE ATTACHED PHOTOGRAPH SHOWS A CLEARLY DEFINED GOUGE AROUND THE FULL CIRCUMFERENCE OF THE TIRE. THIS PROVES THAT THE SUSPENSION BROKE WHILE THE CAR WAS TRAVELLING ALONG AND WAS NOT THE RESULT OF A COLLISION. YOU SHOULD BE AWARE OF THE CASE OF MASSOUD V TESLA HTTPS://WWW.PLAINSITE.ORG/DOCKETS/3Z2ZFTGN3/SUPERIOR-COURT-OF-CALIFORNIA-COUNTY-OF-LOS-ANGELES/MENA-MASSOUD-V-TESLA-MOTORS-INC-A-DELAWARE-CORPORATION/ THE INSURER PROVED THAT THE CRASH WAS THE RESULT OF SUSPENSION FAILURE. PHOTOGRAPHS OF THE CRASH SCENE PROVED THAT THE SUSPENSION SNAPPED AND THE BASE OF THE CAR LEFT SKID MARKS ON THE ROAD BEFORE IT FINALLY COLLIDED WITH A GUARD-RAIL. THIS CASE WAS SETTLED OUT OF COURT AND TESLA INSISTED UPON THE USUAL NON-DISCLOSURE AGREEMENT PLEASE DEMAND THAT TESLA RECALL THESE DEADLY CARS. THANK YOU. KEEF.

BOTH FRONT DOOR AT THE BOTTOM HAS SHARP EDGE THAT SLICE MY LEG WHEN I WORK OUT OF THE CAR. AT 65 MPH ON FREWAY WITH MINOR ROUGH SURFACE, VEHICLE ZIG ZAG SWAY BACK AND FORTH. ONLY ON MINOR ROUGH ROAD FREEWAY SURFACE