2024-2025 Tesla Cybertruck Halfshaft Bolts Grinding Noise TSB

Symptoms

Owners of certain 2024-2025 Tesla Cybertruck vehicles may notice a loud grinding noise. This symptom occurs if the halfshaft bolts lose torque, which can cause the hub and axle facespline teeth to become unseated and damaged.

Diagnosis and Trigger Conditions

The repair procedure for the Tesla Cybertruck halfshaft bolts depends on whether the loud grinding noise is present. If the noise is heard, it indicates potential damage to the hub and axle facespline teeth. If no noise is present, the repair focuses solely on replacing the halfshaft bolts.

Technicians will also check the vehicle's software version. If the software is FSD (Supervised) 14.2.1.25 or earlier, or 2025.44.3 or earlier, it must be updated to FSD (Supervised) 14.2.1.25 or later, or 2025.44.3 or later, before proceeding with the repair.

Important Warnings for Owners and Technicians

Tesla has issued several critical warnings regarding the repair of the Tesla Cybertruck halfshaft bolts:

• Do not reuse bolts: "Do not reuse the existing bolt. Only install a new bolt." Halfshaft bolts are single-use and must be replaced if the adhesive bond is broken.
• Torque modification: "Do not tighten or loosen the bolt after the initial torque (300 Nm) is properly set. Modifying the torque on the bolt after it has been set may break the adhesive bond, causing the bolt to loosen."
• Adhesive curing time: The new halfshaft bolt has an adhesive thread patch that requires approximately 2 minutes to cure. Do not allow more than 2 minutes to pass before continuing to the next step after hand-tightening.
• Spline alignment: Ensure the splines on the hub and halfshaft are properly aligned before tightening the halfshaft bolt.
• Axle bolt force: When tightening the axle bolt, "do not apply force on the bolt head in the inboard vehicle direction to prevent unseating the face splines."
• Double Pedal Torque Check safety: This routine builds high motor torque at a standstill. "DO NOT perform the following steps indoors or without adequate space in front of or behind the vehicle in case of sudden vehicle movement during the routine." This warning is repeated multiple times throughout the bulletin.

Repair Procedure Summary

The repair procedure for the Tesla Cybertruck halfshaft bolts varies based on the presence of grinding noise:

If axle grinding noise is present:

1. The hub, halfshaft, and halfshaft bolt on the impacted axle will be replaced. This may involve replacing the LH and/or RH Front Hub, LH and/or RH Rear Hub, LH or RH Front Halfshaft, LH and RH Front Halfshafts, LH or RH Rear Halfshaft, or LH and RH Rear Halfshafts.
2. The remaining halfshaft bolts on unaffected locations will also be replaced.
3. After replacement, a "Double Pedal Torque Test" is performed to confirm proper seating of the hub and halfshaft facespline teeth.

If no axle grinding noise is present:

1. All four halfshaft bolts will be replaced.
2. A "Double Pedal Torque Test" is performed to confirm proper seating of the hub and halfshaft facespline teeth.

General steps for bolt replacement:

• The LH front wheel cover is removed.
• The existing halfshaft bolt is loosened with a breaker bar and discarded.
• An assistant helps push the halfshaft towards the hub while rotating it to lock the facesplines.
• A new halfshaft bolt is installed and hand-tightened, ensuring proper spline alignment.
• The new halfshaft bolt is tightened to 300 Nm.
• The LH front wheel cover is reinstalled.
• These steps are repeated for any remaining halfshaft bolts.

Double Pedal Torque Test:

1. The vehicle is driven to an empty parking area with at least 25 feet of clear space in front and behind.
2. A laptop with Toolbox 3 is connected to the vehicle.
3. The "Double Pedal Torque Check" routine is initiated in Toolbox, and instructions are carefully reviewed.
4. The test is performed as instructed. If the test fails and grinding noise is heard, the hub, halfshaft, and halfshaft bolt on the impacted axle are replaced again, and the test is re-run.

Required Tools or Parts

Technicians will require specific parts for this repair:

• Required for all repairs:
  • 2009788-00-A: BLT,HHL,M16-1.5x80,[109],G0410,SM,A02 (Quantity: 4)
• If necessary (based on diagnosis):
  • 1250171-00-D: DRIVEN HUB - 6X139.7MM PCD - 180MM FLANGE (Quantity: 1-4)
  • 1250161-00-C: HALFSHAFT - 33.4MM X 588MM SHAFT - REAR (Quantity: 1-2)
  • 1250119-00-B: HALFSHAFT - 34MM X 592MM SHAFT - TRIMOTOR (Quantity: 1-2)
  • 1250169-00-B: HALFSHAFT - 42MMX 498MM SHAFT - REAR - TRI MOTOR (Quantity: 1-2)

Owner Action

If you own a 2024-2025 Tesla Cybertruck and experience a loud grinding noise or are concerned about the halfshaft bolts, it is recommended to contact your authorized Tesla service center. This is a campaign bulletin, indicating it addresses a non-safety-related condition and provides recommended technical diagnosis and repair procedures. The service center will determine the applicability of this bulletin to your specific vehicle and perform the necessary inspection and repair.

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Source: NHTSA ID: 11030614