NHTSA Safety Complaint

palmer_md · Mar 20, 2013

I've been following this issue discussed in other forums, and searching here I did not see anything. I hope I'm not duplicating threads, if so, please move to the correct location.

The Long Tail Pipe: Tesla's first "safety complaint" lodged against the Model S - might there be quality control problems?

complaint said:
Date Complaint Filed: 02/17/2013
Component(s): STRUCTURE Date of Incident: 02/14/2013
NHTSA ID Number: 10498446
All Products Associated with this Complaint
Details
0 Associated Documents
Crash:No Fire:No Number of Injuries:0 Number of Deaths:0
Manufacturer: TESLA MOTORS, INC
Vehicle Identification No. (VIN): 5YJSA1DN9DF...
SUMMARY:
I REMOVED THE REAR BUMPER COVER FROM THE CAR TO INSTALL A TRAILER HITCH. THREE OF THE FOUR NUTS WERE NOT TIGHTENED ON THE RIGHT SIDE OF THE STEEL BUMPER CROSS MEMBER. THE NUTS WERE LOOSELY STARTED ONTO THE STUDS. THE NUTS ARE LOCATED IN AN AREA THAT CANNOT BE INSPECTED WITHOUT DISASSEMBLING THE REAR OF THE CAR. I BELIEVE THIS IS A SERIOUS SAFETY ISSUE AS IT AFFECTS CRASH CRUMPLE ZONE INTEGRITY AND PROTECTION FOR THE REAR FACING JUMP SEATS IN THIS VEHICLE. THERE WAS NO ACCIDENT AND I DO NO BELIEVE THERE IS A DESIGN PROBLEM. HOWEVER, THERE IS AN ASSEMBLY QUALITY CONTROL ISSUE. *TR

Beckler · Mar 20, 2013

Not many details here. A complaint itself doesn't mean much, does it? Who's filing this anyway? If an owner, then suddenly they're an expert on vehicle structure, crumple zones and manufacturing process? If some random technician, then doubly so. None of which means there couldn't be some issue, however.

palmer_md · Mar 20, 2013

I'm not sure I'd have filed a complaint to the NHTSA for finding a bolt loose, but I can see how someone else might feel compelled to do so. I don't think there is a quality control issue, but it is something that Tesla needs to get out in front of. In the other forum there were some Anti-Tesla folks (actually anti-EV) that really jumped on this as a first sign that Tesla was in trouble. They were predicting a recall of the cars to inspect bolts and that the recall would damage the company. Kind of silly, but this is also not something that Tesla can ignore.

Zextraterrestrial · Mar 20, 2013

I thought there was a thread with the Torlift install where they mentioned the loose bolts ~ 3 out of 4 or something that were only hand tightened but wouldn't change the crash wortyness of the car.
It was more than 1 month ago..

bluetinc · Mar 20, 2013

Here is the original thread:

(With Pictures)

Check Your Nuts! Found Assembly Error During Hitch Install | Forums | Tesla Motors

kevincwelch · Mar 20, 2013

I suspect it's a rare occurrence to see something that looks like a line worker was interrupted in the middle of a job. However, given this incident, the gaps, panel alignment issues (now on Edmunds!) and the end of year rush, hopefully these QC issues are behind Tesla.

My car was started in 2013, and I've noticed only two QC issues: chrome on driver's door does not align with passenger door and the leading edge of the frunk appears to have a vertical gap of about 5mm making it appear not fully closed. Other than that, no observed defects in quality.

Perhaps at annual servicing, Tesla should take off the fascia and check out these various potential bolt issues.

jeff_adams · Mar 20, 2013

Not doubting this report, but I fully expect to see several negative "issues" reported with the car. There are a lot of industries that want to see a Tesla failure. There will be smear campaigns......

kevincwelch · Mar 20, 2013

I think the author was a little premature in sending a report to NHTSA. Would have first escalated through Tesla and judged their response to the issue and what they were going to do to investigate/correct.

Zzzz... · Mar 20, 2013

I know Ford, and probably other automakers use specialized tools that electronically control how many revolvements tool made to tighten the nut. And worker supposed to tighten them in special order, all stats are controlled/recorded and worker just could not not tighten nut because of whatever reason, or at least such thing would be recorded...

Excuse my English.

doug · Mar 20, 2013

bluetinc said:
Check Your Nuts! Found Assembly Error During Hitch Install | Forums | Tesla Motors

Phrasing!

AnOutsider · Mar 20, 2013

doug said:
Phrasing!

haha, glad I wasn't the only one to spot that.

NigelM · Mar 20, 2013

Zextraterrestrial said:
I thought there was a thread with the Torlift install where they mentioned the loose bolts ~ 3 out of 4 or something that were only hand tightened but wouldn't change the crash wortyness of the car.
It was more than 1 month ago..

Looks like that and the complaint are one the same.

wycolo · Mar 20, 2013

Looking at the 3 loose nuts (out of 8) does it look like those bolts are amber in color, implying the bolts are made of plastic? Or maybe they are anodized? Also it appears there is nothing hanging on that black 'bumper' piece, that it is wrap-around thus not likely to fall off even w/o any nuts at all. The hitch appears to be mated to a lower crosspiece, actually housed within it, so the lower crosspiece is doing all the heavy lifting wrt the hitch. Lot going on here.

Re any recall: taking everyone's S apart to 'look see' runs the risk of bolts being left untightened, or other surprises! When any process becomes routine, inattention to detail can arise. Should my S be flagged due to closeness of VINs to the subject car, I'm not sure I would put it thru this process. I just might put one of these hitches on anyway, thus the effort would go to good use!
--

montgom626 · Mar 20, 2013

We have no evidence this is true.

Sancann · Mar 20, 2013

This was discussed in detail on the Tesla forum. The owner who found it and reported it was Pungoteague_Dave. He reported it to Tesla and NHTSA at the same time. Tesla checked his car thoroughly and came to the conclusion it had to be an anomaly. Here is the link to the discussion.

Check Your Nuts! Found Assembly Error During Hitch Install | Forums | Tesla Motors

K Hall · Mar 20, 2013

Opened a federal case over 3 loose nuts? Amusing at best.

palmer_md · Mar 20, 2013

I think he just jumped the gun on reporting it to NHTSA. The original poster alluded to that as well without actually saying it. Thanks to those who pointed to the discussion on the Tesla website, it was an interesting read. I did not find that on a quick search on my own. At least the saga ended well with the original poster saying:

After a fast run around DC and over to Annapolis today, I continue to be blown away by how great this car is. I consider the bumper nut saga to be over at this point, probably a symptom of the year-end rush to get cars out, and a lesson learned at the factory.

brianman · Mar 22, 2013

Maybe it's just me but...

I REMOVED THE REAR BUMPER COVER FROM THE CAR TO INSTALL A TRAILER HITCH.

Technically, isn't the proposed action a warranty voiding activity?

jerry33 · Mar 22, 2013

brianman said:
Maybe it's just me but...

Technically, isn't the proposed action a warranty voiding activity?

As far as the bumper is warrantied, I suppose. It won't have any effect on any other part of the warranty.

ChadS · Mar 22, 2013

And even on the bumper, the warranty is only "voided" if there is a problem AND Tesla can prove the problem was caused by the hitch. Which, to my mind, is a perfectly good reason for the warranty to be invalid.

Tesla can't refuse to fix the car - or even certain parts of the car - just because there is a hitch on it.

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