2024-2026 Tesla Cybertruck Tailgate Delamination TSB

Symptoms

Owners of 2024-2026 Tesla Cybertruck vehicles may experience noise, vibration, and harshness (NVH) originating from the tailgate. This condition is typically caused by the adhesive in the tailgate's top edge and/or center reinforcement bracket delaminating.

Diagnosis / Trigger Conditions

To diagnose the Tesla Cybertruck tailgate delamination, technicians will inspect the tailgate for symptoms related to the condition. This involves checking the tailgate's top edge and center reinforcement bracket area for any signs of delamination. Pressing on the top edge of the tailgate helps identify separation along the top applique seam.

Additionally, pressing on the center of the tailgate helps check for any panel flex, which can indicate adhesive failure. If either the top edge separates or the center of the tailgate flexes, a rework or replacement procedure is necessary.

Repair Procedure Summary

Addressing the Tesla Cybertruck tailgate delamination involves a multi-step process, which may include rework or full replacement of the tailgate assembly. The procedure begins with a thorough inspection of the tailgate's top edge and center reinforcement bracket for delamination.

If rework is required, the technician will first prepare the vehicle by opening the front door, lowering the window, and opening the tailgate and tonneau cover. A support stand is then positioned under the tailgate. Several components must be removed, including the tailgate inner cover (Service Manual procedure 1215125031), tailgate lamp (1740115061), cinching latches (1133116041), manual release cables (1120122081), and tailgate harness (1710095011).

The center reinforcement bracket is inspected to determine if it's a 1-piece or 2-piece design. Old adhesive is then carefully removed from delaminated areas using specialized tools like a scraper, razor blade, and wire brush, often aided by a heat gun. After vacuuming debris, the surfaces are cleaned with Isopropyl Alcohol (IPA) wipes and allowed to dry.

New adhesive, PLEXUS 8110, is applied along the edges where the center reinforcement bracket meets the tailgate and to the top edge of the tailgate. Slight pressure is applied to ensure proper adhesion. After cleaning the exterior surface, four 25 LB ballast bags are placed on the supported tailgate for one hour to allow the adhesive to cure. Finally, all removed components are reinstalled (Service Manual procedure 1010025012).

Required Tools or Parts

Technicians will require specific parts and special tools to perform the repair for Tesla Cybertruck tailgate delamination:

Parts Required:

• PLEXUS 8110 (Part Number: 2259705-00-A)
• If necessary, Tailgate Assembly (Part Numbers: 1812358-CB-A, 1812358-FB-A, 1812358-FS-A, 1812358-NF-A)

Special Tools:

• 500 LB PORTABLE BENCH (Part Number: 1054720-00-A)
• WIRE BRUSH (Part Number: 1081542-00-A)
• CUT RESISTANT GLOVES
• SCRAPER, RAZOR BLADE
• BALLAST BAG, 25 LB (x4) (Part Number: 1145158-00-A)
• Cordless Heat Gun (Part Number: 1706381-00-A)

Shop Supplies:

• Isopropyl Alcohol (IPA) Wipes
• Sandpaper

Important Warnings

Technicians performing this repair must observe critical safety precautions. WARNING: The edges on the interior of the tailgate assembly can be very sharp. Make sure to wear appropriate Personal Protective Equipment (PPE) such as cut-resistant gloves when working on or around the interior of the tailgate.

Owner Action

If you own a 2024-2026 Tesla Cybertruck and notice noise, vibration, or harshness from the tailgate, it is recommended to contact your authorized Tesla service center. They can diagnose the issue and perform the necessary inspection, rework, or replacement of the tailgate assembly as outlined in Service Bulletin SB-25-10-006.

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Source: NHTSA ID 11025857