Tesla Recalls 6,197 Cybertrucks Over Light‑Bar Adhesive Issue

Tesla has announced a voluntary recall of 6,197 units of its Cybertruck pickup in the United States, after determining that the adhesive used to mount an optional off‑road light bar may not be properly bonded to the vehicle’s windshield.

⚠️ Recall Alert
2024 Tesla Cybertruck vehicles equipped with a service-installed off-road light bar accessory.
Recalled because off-road light bar may detach and become a road hazard.https://t.co/0nkpRYIqYo

— NHTSA Recalls & Ratings (@NHTSArecalls) October 30, 2025

What’s the problem?

According to the filing with the National Highway Traffic Safety Administration (NHTSA), the issue centres on a service‑installed optional LED light bar accessory, which in some cases "may have been inadvertently attached … using the incorrect surface primer."

• The root cause was identified as the primer designated BetaPrime, which Tesla says was not appropriate for bonding the light‑bar assembly to the windshield glass. 

• The component in question is produced by Hella Romania S.R.L.. Although Tesla states the primer itself was not defective in quality, it was the wrong choice for this application.

• The hazard lies in the possibility that the light bar could detach while the vehicle is in motion, potentially becoming a road hazard to other drivers.

Scope & impact

• The recall covers approximately 6,197 vehicles in the U.S. market. To date, Tesla reports 619 warranty claims tied to this condition and one field report of the light bar detaching. Importantly, there have been no reported crashes or injuries associated with this issue. 

• Owners of affected vehicles will be notified and service centres will undertake the remedy free of charge.

How Tesla plans to fix it

From Tesla's recall bulletin:

"At no charge to customers, Tesla will inspect the service‑installed optional off‑road light bar accessory for delamination or damage and if either is present, replace the light bar with a new light bar adhered with tape and a positive mechanical attachment. If no delamination or damage is present, Tesla will retrofit the service‑installed optional off‑road light bar accessory with a positive mechanical attachment."

In effect, the fix shifts the mounting method from relying purely on adhesive to adding a positive mechanical attachment (such as a bracket or fastener) alongside adhesive tape, reducing sole dependence on chemical bonding. 

The recall follows a string of quality and safety issues for the Cybertruck. Notably:

• Earlier in 2025, Tesla recalled over 46,000 Cybertrucks because an exterior stainless‑steel trim panel could detach, also due to adhesive/attachment issues. 
  
• This latest recall highlights persistent challenges in translating the Cybertruck’s unique design features (such as stainless‑steel exoskeleton and large accessory modules) into assembly and service processes that meet standard mass‑production durability expectations.

For owners and potential buyers:

• If your Cybertruck is equipped with the optional off‑road light bar, it’s worth checking with Tesla whether your vehicle is included in the recall.
• Even if you have not observed any issue (e.g., detachment or looseness), Tesla’s remedy requires inspection and likely retrofit, so proactive compliance will avoid future hassle.
• Given that no injuries have been reported to date, the risk appears low, but the potential road‑hazard nature of a flying component (especially at highway speeds) warrants action.