Tesla initiates rare physical recall for 2016 Model X over appliqué issue

Tesla has initiated a rare physical recall for the 2016 Model X SUV. As per the National Highway Traffic Safety Administration’s (NHTSA) Safety Recall Report, a total of 9,136 units of the 2016 Model X that were produced through July 31, 2016 are affected by the issue. 

The Tesla Model X is equipped with a cosmetic front appliqué just behind the windshield, as well as a spine appliqué at the center of the roof in between the falcon door roof glass. Both appliqués are attached to the vehicle using urethane. If not enough primer was used in the appliqué-to-urethane interface, the adhesion of the part could weaken, and the appliqué could separate from the Model X. Such an issue could be a traffic hazard, especially if the appliqué comes off while the 2016 Model X is in motion.

Interestingly enough, Tesla already initiated a physical recall in November 2020 to inspect 2016 Model X units for proper appliqué retention. At the time, Tesla used an inspection method that involved pulling the appliqué in several areas with a maximum force of 60N. If the components weathered the 60N pull inspection, they were not replaced. Tesla has now determined that either the inspection pull force or the location and number of locations where the pull force was applied in the 2020 recall were not sufficient to accurately identify faults in the component. 

To address this issue, Tesla will be inspecting affected 2016 Model X vehicles and perform an improved retention test with a higher pulling force at a minimum of 120N. If the appliqué passes the retention test and shows sufficient adhesion, then no further action would be necessary. If the appliqué fails the retention test, Tesla Service will reattach the affected component using the proper primer and urethane procedure. A full replacement for the appliqué would also be performed if needed. 

It should be noted that the appliqué issue seems to be present only on 2016 Tesla Model X units that were produced through July 31, 2016. Following this date, the supplier of the component implemented new processes to standardize and document its primer application, addressing the appliqué adhesion issue. 

The NHTSA’s Safety Recall Report about the 2016 Tesla Model X’s appliqué issue can be viewed below. 

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