Tesla Cybertruck Wheel Stud Holes Could Crack

A recently announced safety defect affects a small number of 2024–2026 Tesla Cybertruck models equipped with 18-inch steel wheels, raising concerns about a potential issue involving brake rotor cracking and wheel stud integrity. While no injuries or crashes have been reported, Tesla has taken action to address a possible long-term safety risk.

What’s the Problem?

On affected Cybertrucks, high-severity road impacts and aggressive cornering can place excessive stress on the brake rotor stud holes. Over time, this stress may cause cracks to form in the rotor, particularly around the stud holes.

If these cracks worsen with continued use, there is a possibility that a wheel stud could separate from the wheel hub — a scenario that could compromise how securely the wheel is attached to the vehicle.

Why This Matters

While the issue develops gradually, the potential outcome is serious:

• A separated wheel stud can affect how the wheel is held in place.
• This may impact vehicle controllability.
• In worst-case scenarios, it could increase the risk of a collision.

It’s important to note that no crashes, injuries, or fatalities have been linked to this issue so far.

How the Issue Was Discovered

The problem was first identified during pre-production testing in August 2025, where engineers observed brake rotor cracking tied to the geometry of the hub and bearing system. Although testing showed no immediate safety failure, Tesla planned improvements to:

• Brake rotor durability
• Lug nut friction to help prevent loosening

However, due to a change management error, these improvements were not implemented when production began on August 28, 2025.

Field Incident and Investigation

The issue surfaced in real-world conditions on October 28, 2025, when a driver reported braking pulsations. By November 5, 2025, Tesla confirmed cracked brake rotors on that vehicle — the only known field case.

Tesla had already launched a broader engineering field study on November 4, 2025, to inspect affected components across vehicles.

Production of Cybertrucks with 18-inch steel wheels was halted on November 25, 2025, largely due to low demand.

Testing and Final Decision

In December 2025, Tesla sent components to suppliers for further testing. Results, completed between February and April 2026, showed:

• No loss of vehicle control.
• No immediate functional failure, even with cracked rotors.

Despite this, Tesla engineers concluded that continued stress over time could eventually lead to wheel stud separation.

The Recall

Out of caution, Tesla issued a voluntary recall on April 14, 2026.

• Tesla Recall Number: SB-26-33-003
• National Highway Traffic Safety Administration Campaign Number: 26V-255
• Affected vehicles: Certain 2024–2026 Cybertrucks built between March 21, 2024, and November 25, 2025, with 18-inch steel wheels

What Tesla Will Do

Tesla will repair affected vehicles free of charge, including:

• Replacing front and rear brake rotors.
• Replacing wheel hubs.
• Installing updated lug nuts.

Owner notification letters are expected to be mailed starting June 20, 2026.