What is the primary symptom of the Tesla Cybertruck halfshaft bolt issue?

The primary symptom is a "loud grinding noise" that can occur if the halfshaft bolts lose torque, causing the hub and axle facespline teeth to become unseated and damaged.

What is the Tesla Service Bulletin number for this issue?

The issue is addressed by Tesla Service Bulletin SB-26-40-001, which details the repair procedure for the loose halfshaft bolts.

What is the "Double Pedal Torque Check" mentioned in the bulletin?

The "Double Pedal Torque Check" is a diagnostic test performed using Tesla's Toolbox 3 software after replacing the halfshaft bolts. It applies high motor torque to confirm that the hub and halfshaft facespline teeth are properly seated.

Are there any important warnings for the repair or diagnostic process?

Yes, technicians are warned not to perform the "Double Pedal Torque Check" indoors or without adequate clear space due to the risk of sudden vehicle movement. Also, care must be taken to ensure proper spline alignment and observe the curing time for the new halfshaft bolts' adhesive.

Is this a safety recall?

No, the bulletin explicitly states that this is a "non-safety-related condition." However, it is still recommended to address the issue to prevent potential further damage.

2024-2025 Tesla Cybertruck Halfshaft Bolt Grinding Noise

Symptoms

Owners of affected 2024-2025 Tesla Cybertrucks may experience a "loud grinding noise". This noise occurs if the Tesla Cybertruck halfshaft bolts lose torque, causing the hub and axle facespline teeth to become unseated and potentially damaged. Addressing this promptly can prevent further wear.

Diagnosis / Trigger Conditions

Before starting the repair, technicians will check the vehicle's software version. The vehicle must be running FSD (Supervised) 14.2.1.25 or later, or 2025.44.3 or later. If the software is older, it must be updated using Service Manual procedure 00020003.

The primary diagnostic step after replacing the halfshaft bolts is to perform a "Double Pedal Torque Check". This test confirms that the hub and halfshaft facespline teeth are properly seated. If the test fails and grinding noise is still present, further replacement of hubs and halfshafts may be required.

Repair Procedure Summary

The repair involves replacing all four Tesla Cybertruck halfshaft bolts. Technicians will first remove the wheel cover (using Service Manual procedure 34015022) and then loosen and remove the existing halfshaft bolt. An assistant will help push the halfshaft towards the hub and rotate it until the facesplines lock into place, as shown in Figure 3 of the bulletin. A new halfshaft bolt is then installed and hand-tightened, taking care not to unseat the splines (Figure 4).

The new bolt, which has an adhesive thread patch, requires approximately two minutes of curing time before final tightening. The bolt is then tightened to 300 Nm (Figure 5), ensuring the splines are properly aligned. This process is repeated for all halfshaft bolts. Following the bolt replacement, a "Double Pedal Torque Check" is performed using Tesla's Toolbox 3 diagnostic software. This test involves building high motor torque at a standstill in a safe, open area to ensure proper seating of the hub and halfshaft facespline teeth. If the test is successful and no grinding noise is heard, the repair is complete. If the test fails and grinding noise persists, the technician will replace the affected hub(s) and halfshaft(s) as necessary, then re-run the torque check.

Required Tools or Parts

The primary part required for this repair is the halfshaft bolt, Part Number 2009788-00-A, described as "BLT,HHL, M16-1.5x80,[109],G0410,SM,A02". Four of these bolts are needed.

If further damage is found after the initial bolt replacement and torque check, additional parts may be required:

DRIVEN HUB - 6X139.7MM PCD-180MM FLANGE (Part Number 1250171-00-D)
HALFSHAFT - 33.4MM X 588MM SHAFT - REAR (Part Number 1250161-00-C)
HALFSHAFT - 34MM X 592MM SHAFT - TRIMOTOR (Part Number 1250119-00-B)
HALFSHAFT - 42MMX 498MM SHAFT - REAR - TRI MOTOR (Part Number 1250169-00-B)

Specialized diagnostic software, "Toolbox 3", is also required to perform the "Double Pedal Torque Check". The bulletin also lists various correction codes for different repair scenarios, ranging from S012640001 to S092640001.

Important Warnings

Do NOT perform the Double Pedal Torque Check indoors or without adequate space. This routine builds high motor torque at a standstill, and there is a risk of sudden vehicle movement. Ensure at least 25 feet of empty space in front of and behind the vehicle.
Ensure proper spline alignment. When tightening the new halfshaft bolt, technicians must avoid applying force on the bolt head in the inboard vehicle direction to prevent unseating the facesplines. The splines on the hub and halfshaft must be properly aligned before tightening.
Observe adhesive curing time. The new halfshaft bolts have an adhesive thread patch that requires approximately 2 minutes to cure. Do not allow more than 2 minutes to pass before proceeding to the next step after hand-tightening.
Secure diagnostic equipment. If using a laptop with Toolbox 3, ensure it is in a safe location within the vehicle in case of sudden vehicle movement during the routine.
Understand test instructions. Technicians must carefully read and understand the instructions for the "Double Pedal Torque Check" before performing the routine.
This is a non-safety-related condition. The bulletin explicitly states this is a "non-safety-related condition".

Owner Action

If your 2024-2025 Tesla Cybertruck exhibits a "loud grinding noise" from the rear drive unit, it is recommended to contact a Tesla Service Center. This issue is addressed by Service Bulletin SB-26-40-001. The repair involves replacing the Tesla Cybertruck halfshaft bolts and performing a diagnostic torque test. While the bulletin states this is a non-safety-related condition, addressing it promptly can prevent further damage to the hub and axle components.

Source: NHTSA manufacturer communication 11028090.