Tesla’s Cybertruck was supposed to be indestructible, but parts started falling off, triggering a recall.
On October 30, 2025, regulators recalled 6,197 trucks due to loose light bars.
This was the eighth recall in 18 months—one every 2.2 months—making it one of the most troubled vehicle launches ever, experts say.
Reservation Graveyard
In 2019, over one million people pre-ordered the Cybertruck, but by early 2025, Tesla had delivered just 46,096 trucks, fulfilling only 4.6% of the reservations.
The slow delivery rate contributed to missing Musk’s promised 250,000 annual sales, with actual sales possibly reaching only 20,000 in 2025.
As a result, nearly 980,000 would-be buyers did not purchase a truck, leading to an estimated $14.7 billion in lost revenue for Tesla.
Price Shock
Prices jumped dramatically from original promises, causing many buyers to cancel. The base model increased from $39,900 to $60,990.
The all-wheel-drive version rose from $49,900 to $79,990. The top model’s price increased from $69,900 to $99,990.
In August 2024, Tesla cancelled the cheapest option and added a $20,000 mandatory package, further prompting cancellations due to sticker shock.
Production Reality
Tesla built factory space for 250,000 Cybertrucks yearly, but demand collapsed. In the first nine months of 2025, only 16,097 were sold—a 38 percent drop from 2024.
Third-quarter sales fell 62.6 percent.
Tesla is expected to sell only 20,000 vehicles in 2025, missing its targets by 92 percent and leaving factories largely idle.
Eight Recalls
Between January 2024 and October 2025, eight safety recalls were issued for the Cybertruck.
Recurring issues—including accelerator pedals detaching, cameras failing, drive systems breaking, wipers stopping, and trim flying off—prompted these recalls.
The March 2025 recall, affecting 46,096 trucks (nearly every one built), far exceeded normal industry rates for new vehicles, underscoring the seriousness and scale of these problems.
Piedmont Tragedy
On November 27, 2024, a Cybertruck carrying four college students crashed into a tree in Piedmont, California.
Driver Soren Dixon, 19, and passenger Jack Nelson, 20, died on impact. The vehicle caught fire. Krysta Tsukahara, 19, couldn’t escape and died from smoke inhalation.
Only Jordan Miller survived after being pulled out.
Trapped Inside
Two families sued Tesla in October 2025, claiming electronic door handles trapped victims in the burning truck and that this design flaw contributed to the deaths.
When the crash cut the electrical power, the doors wouldn’t open. Although manual releases exist, they require removing carpet to reach a hidden metal loop, making escape difficult.
The lawsuits argue that Tesla was aware of this risk but continued to sell vehicles unchanged, ultimately leading to these tragic outcomes.
NHTSA Investigation
On September 15, 2025, federal safety regulators investigated Tesla door handles after nine complaints. In four cases, parents smashed windows to rescue children trapped in Model Y vehicles when doors wouldn’t open.
The investigation encompasses 174,300 vehicles and may be expanded to include other Tesla models. Regulators worry about entrapment in emergencies, such as hot cars.
Previous Deaths
The Piedmont crash wasn’t the first. In 2024, five people died in a Wisconsin Model S fire, allegedly trapped by failed door handles—an issue similar to the Cybertruck incident.
Families claim victims screamed for five minutes as flames spread. Another Model 3 driver burned beyond recognition after being trapped.
Bloomberg documented multiple cases where Tesla power failures prevented escape, underscoring how this recurring issue with the door handle has led to fatalities across various models.
Two Weeks Notice
On November 10, 2025, Siddhant Awasthi, Cybertruck program manager, quit after eight years at Tesla.
He left just 11 days after the latest recall and three weeks after families filed death lawsuits.
In a LinkedIn post, he called it “one of the hardest decisions” but didn’t explain why. Observers noted the suspicious timing.
Intern to Executive
Awasthi joined Tesla as an intern in August 2017 after earning an engineering degree.
He quickly impressed leaders and was promoted repeatedly—first to project engineer in 2018, then to program manager in 2019, and finally to senior manager in 2020.
By 2022, at the age of 30, he led the entire Cybertruck program, reporting directly to Musk. His rise symbolized opportunity at Tesla.
Recall Comparison
Auto manufacturers averaged 4.8 recalls across all models over a 15-month period.
The Cybertruck alone had eight recalls in 18 months—more than triple the industry rate. The March 2025 recall affected virtually every truck.
Analysts say this positions it among the worst launches.
Design Compromises
The stainless-steel body caused manufacturing problems. Designer Franz von Holzhausen explained that thick steel can’t be stamped normally, forcing the use of unusual construction methods.
Tesla used adhesive instead of welding for its panels, resulting in two recalls when parts fell off.
The hard steel also compromised crash safety—testing revealed higher head impact forces than those of competing trucks.
Safety Ratings
Safety testers gave the Cybertruck “good” ratings for front crashes but denied it top awards. Headlights received the worst “poor” rating for nighttime visibility.
Seat belt reminders received a rating of “marginal,” and child seat anchors received a rating of “acceptable.”
The “good” crash rating only applies to trucks built after April 2025 improvements. Earlier models likely score lower.
Door Redesign Coming
On September 17, 2025, Tesla’s design chief announced plans to fix the door handle problem, responding to safety concerns.
Franz von Holzhausen said that electronic and manual releases would be combined into one button, addressing failures exposed during emergencies. He admitted the current design fails “in a panic situation.”
Tesla didn’t specify when the fix would be implemented or if existing trucks would be updated, leaving uncertainty about any immediate safety improvements.
Regulatory Momentum
Tesla faces multiple government investigations beyond door handles. One examines whether Tesla failed to report crashes in a timely manner.
Another investigates the “Summon” self-parking feature after collision reports. A third covers 2.4 million Teslas after a pedestrian death.
Consumer groups want mandatory, accessible manual door releases that meet federal safety standards.
Industry Ripples
Tesla’s door problems are changing the entire auto industry because regulators and competitors see the risks. Chinese regulators may ban fully electronic door handles in response to safety concerns raised by incidents involving Tesla.
Ford, GM, and Stellantis are reviewing their electronic door systems to avoid similar problems. Safety engineers issued 2025 guidelines stating that manual releases must be “immediately obvious,” specifically due to events like those involving Tesla.
Crash testers are developing new tests for door operability after power loss in response to these failures.
Social Media Backlash
Owners created Facebook groups and Reddit forums documenting Cybertruck problems. TikTok videos of flying trim panels got millions of views.
YouTube channels created a “failure” series. The hashtag #CybertruckRecall trended repeatedly on X.
Some false claims spread about exploding batteries, but real complaints about rusting steel and malfunctions damaged Tesla’s reputation.
Automotive Flops
The Cybertruck joins infamous failures. The DeLorean made 9,000 cars before bankruptcy. GM’s EV1 was built in only 1,117 units before being discontinued.
The Tucker 48 managed just 51 units. Ford’s Edsel lost $350 million.
However, the Cybertruck is unique: Tesla has built capacity for 250,000 units per year yet sells only 20,000—possibly the largest manufacturing-to-sales gap in history.
Bottom Line
The Cybertruck demonstrates engineering ambition, but its failure to deliver reliable performance has led to eight recalls in 18 months, exposing significant quality shortcomings.
This drop in dependability resulted in sales 92 percent below targets and a 63 percent year-over-year decline. Fatal crashes allegedly caused by the door handles triggered investigations and lawsuits, highlighting the safety impact of those design choices.
The program manager’s departure further signals internal trouble. Ultimately, bold design failed because essential reliability and safety were not ensured, resulting in downstream operational and reputational harm.