2025 Tesla Cybertruck Door Shaking and Noise TSB

Symptoms

Owners of 2025 Tesla Cybertruck vehicles may notice specific issues related to their door assemblies and left-hand (LH) side mirror. These symptoms typically manifest as low-pitched booming, shaking, rattling, and/or vibrations.

The problem occurs at the door assemblies and/or the LH side mirror, particularly when the vehicle is driven at high speeds, specifically greater than 60 mph (96 km/h). These conditions do not meet Tesla's quality standards, indicating a potential manufacturing concern that leads to the Tesla Cybertruck door shaking.

Diagnosis / Trigger Conditions

To diagnose the issue, technicians will perform a test drive on the highway at speeds exceeding 60 mph (96 km/h). During this drive, they will listen for low-pitched booming or vibrations emanating from the doors and observe the LH side mirror glass for any visible shaking or rattling.

It is important to note the specific location of the noises, such as the LH front door, the front or rear of the vehicle, or if the issue is widespread. If no low-pitched booming, vibration, or LH side mirror shaking is observed during high-speed driving, the vehicle is not affected by this bulletin, and correction code S012510002 will be used. If symptoms are present, the repair procedure will proceed, using correction codes S022510002, S032510002, or S042510002 depending on the scope of the repair.

Important Warnings

When performing the repair, technicians must adhere to specific safety and procedural guidelines:

• "WARNING: Read the adhesive instructions and safety datasheet to achieve optimal adhesion and to ensure personal safety. If instructed, use appropriate Personal Protective Equipment (PPE), such as protective gloves and a respirator mask."
• "CAUTION: Do not apply adhesive to the drain holes (x2) at the bottom of the front and rear ends of the front door assembly (Figure 8)."
• "NOTE: Make sure adhesive is applied from the tops of the brackets down to the bottoms of the brackets, just before the drain holes."

Repair Procedure Summary

The repair addresses the Tesla Cybertruck door shaking by reinforcing the internal door structures. The procedure involves several steps for both front and rear door assemblies.

Front Door Rework:

1. The LH front door closeout panel is removed, following Service Manual procedure 1150040051.
2. Old adhesive is cleaned from the edges of the reinforcement brackets where they meet the inner door panel, using tools like a wire brush, gasket scraper, and Isopropyl Alcohol (IPA) wipes. Figures 1, 2, 3, and 4 illustrate these areas.
3. New adhesive is then applied to these cleaned reinforcement bracket and inner door panel joints, as shown in Figures 5, 6, and 7.
4. Any remaining butyl patch residue from the forward upper section of the inner front door panel is removed (Figures 9 and 10).
5. The inner door panel is prepared for additional butyl patch installation by cleaning the indicated areas with IPA (Figure 11).
6. Five new NVH butyl patches are installed on the inner door panel (Figure 12), followed by four additional butyl patches on top of the lower ones (Figure 13). These patches are then wet out with a pressure roller.
7. Depending on the initial test drive findings, the rework steps (2-6) may be repeated for the RH front door assembly.

Rear Door Rework:

1. The LH rear door closeout panel is removed, following Service Manual procedure 1150040112.
2. The areas where the reinforcement brackets meet the inner rear door panel are cleaned with IPA wipes (Figures 1 and 3).
3. New adhesive is applied to these reinforcement bracket and inner rear door panel joints.
4. Similar to the front doors, any existing butyl patch residue is removed (Figures 9 and 10).
5. The panel areas are cleaned, and five new butyl patches are installed (Figures 12 and 14), followed by four additional patches (Figure 13), which are then wet out with a pressure roller.
6. These steps (14-22) are then repeated for the RH rear door assembly.

After the rework, the adhesive is allowed to cure for at least two hours. All removed parts are reinstalled, MV power is reconnected, and a final test drive is conducted at speeds over 60 mph (96 km/h) to confirm the repair and ensure the Tesla Cybertruck door shaking issue is resolved.

Required Tools or Parts

To perform this repair, the following parts and special tools are required:

Parts:

• 1004969-00-A: NVH BUTYL FOIL (9 pieces per door, maximum of 36)
• 2220427-00-A: PLEXUS MA8120 ADHESIVE - 50 mL (2 pieces per door, maximum of 8)

Special Tools:

• 2220406-00-A: 2-PART ADHESIVE DISPENSING GUN – 50ML
• 2220800-00-A: 1:1, 2:1 ADHESIVE MIXING NOZZLE
• 1082495-13-A: GASKET SCRAPER
• 1064740-00-A: SCRAPER, RAZOR BLADE
• 1588904-00-A: GLASS GAP AND FLUSH TOOL
• 1454796-00-A: WINDOW SWITCH TOOL
• 1081542-00-A: WIRE BRUSH
• 1465974-00-A: TOOL, PRESSURE ROLLER

Shop Supplies:

• Isopropyl Alcohol (IPA) wipes

Owner Action

If you own a 2025 Tesla Cybertruck and experience symptoms such as low-pitched booming, shaking, rattling, or vibrations from your door assemblies or LH side mirror, especially at speeds above 60 mph (96 km/h), it is recommended to contact your authorized Tesla service center. Inform them of the symptoms you are experiencing. The inspection and repair outlined in Service Bulletin SB-25-10-002 will be performed upon customer complaint to address the Tesla Cybertruck door shaking.

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Source: NHTSA ID 11023639