Falling Temperatures Reveal A Tesla Cybertruck Manufacturing Defect Which Can Lead to the Truck’s 7th Hardware Recall – “Front Differential Fluid Was Underfilled by About an Inch or So in Early Models”

Today, we have reports of a new Cybertruck defect that has the potential to trigger another recall. This will be the Cybertruck’s 7th hardware recall in less than a year.

The information comes from an early Cybertruck owner, John, from Chisago, Minnesota, who was recently contacted by Tesla to fix a manufacturing defect with his front differential.

Interestingly enough, initially, John reached out to Tesla for a completely unrelated issue after his Cybertruck’s FSD computer stopped working.

However, on his way to the service center, John saw a message that said, “Front differential service was due.” This was surprising because John’s Cybertruck only had 17,000 miles.

Once he took the truck into service, John learned that the front differential fluid was not properly filled on his Cybertruck from the factory.

In addition to the problem with his Cybertruck, John was also able to ascertain from a Tesla service technician that the issue affected other early Cybertruck builds.

What’s surprising here is that this issue apparently was not picked up during the warmer months; however, according to the Tesla service technicians, the cold and the change in pressure have brought the problem to the forefront.

John shared the details of what he learned on the Cybertruck Owners Club forum. The Cybertruck owner broke down what happened, starting with the problem with his FSD computer/cameras and going on to the issue with the front differential.

Here is what he wrote…

“I had my FSD and cruise control stop working. The screen wouldn't show the lines in the road or stoplights anymore, just the other vehicles around me. Then, the cameras stopped working altogether.

A couple of days later, they started working again with still no FSD or cruise control available, and lines on the road were not showing. Also, there was no lane departure and no blind spot detection either. I made an appointment, and two weeks later, I got in.

On the way to the service appointment, a message popped up that said front differential service was due, which I thought was strange since I only have 17k miles on it.

The service guy at check-in told me that the front differential fluid was underfilled by about an inch or so on early models and that in the cold here in Minnesota, a change in pressure triggers the warning.

My VIN is 10k, in case you’re wondering. They had it for 4 days, replaced the computer they said was stuck in a boot loop, and topped off the differential."

Most people would be unhappy if they were forced to deal with such a basic issue in a hundred-thousand-dollar vehicle, and others would be wondering how driving 17,000 miles with an underfilled differential fluid have harmed their vehicle.

However, John seems more understanding of Tesla’s shortcomings and says he still loves his Cybertruck. He adds that it’s not his intention to disparage the vehicle and that he’s only sharing the issue to inform other Cybertruck owners which might have trucks with similar defects.

Here is what he wrote…

“I am not posting this to bash my truck; I love this thing! I am just worried that if they were underfilling the differential from the factory for a while, some of you in warmer climates might not know if your level is possibly a bit low.”

Tesla Cybertruck 7th hardware recall

As John learned from Tesla service technicians, it’s not only his truck that has the improperly filled front differential fluid, but it appears that this defect is widespread among other early Cybertruck builds.

Why is this concerning? Without the proper differential fluid level, the differential gears can grind with each other, which can lead to overheating and loss of power.

If the differential failure happens on the highway, it has the potential to lead to a major accident. Personally, I think this looks like a type of defect that the National Highway Traffic Safety Administration (NHTSA) would be interested in investigating.

How widespread is the issue?

Given that Tesla famously doesn't respond to media requests, it’s difficult to ascertain how many Cybertrucks are affected.

Tesla is aware of the defect, and it appears that the EV maker has chosen to deal with the problem only after the vehicle software triggers a warning about the low differential fluid.

In the short term, this will save Tesla money and, more importantly, service technician time. However, if Tesla does not address the defect quickly, it might cause bigger problems.

In addition to the major loss of power concern, the differential defect can also cause significant damage to the sidewalls of the tires, severely uneven tire treads, and strange vibrations or strange sounds, such as humming, grinding, or high-pitched whining.

If you have spent any time looking at the real-world experience of Tesla Cybertruck owners, a lot of them report hearing these winning noises, and countless more have shared their surprise after their tires experienced severely uneven tread wear.

I think it’s fair to assume that at least some of the noise complaints and tire problems are associated with the improperly filled differential fluid.

If Tesla chooses to ignore this problem until things have worsened, the EV maker will not only have to top off the differential fluid but will also need to get the owners new tires and other drivetrain components, including perhaps a full motor replacement.

Overall, it’s surprising to see Tesla might need to issue a 7th Cybertruck hardware recall in less than a year. Please let me know what you think in the comments. Share your ideas by clicking the red “Add new comment” button below. Also, visit our site, torquenews.com/Tesla, regularly for the latest updates.

Image: Courtesy of Tesla, inc.

For more information, check out: First Dad to Let His 16-year-old Son Take a Driver’s License Test in a Tesla Cybertruck Raises Safety Concerns – “That’s a Lot of Acceleration for a 7,000 Pound of Steel”

Tinsae Aregay has been following Tesla and the evolution of the EV space daily for several years. He covers everything about Tesla, from the cars to Elon Musk, the energy business, and autonomy. Follow Tinsae on Twitter at @TinsaeAregay for daily Tesla news.