Dive Brief:
- Tesla has recalled nearly 13,000 Model Y SUVs and Model 3 sedans due to a battery hardware defect that may result in a loss of drive power while the vehicle is moving, according to the National Highway Traffic Safety Administration.
- The recalled vehicles include the 2026 Model Y manufactured between Mar. 15 and Aug. 15, 2025, and 2025 Model 3 produced between Mar. 8 and Aug. 12, 2025. Roughly 1% of vehicles are estimated to have the defect.
- Tesla Service Centers will replace the battery hardware free of charge. The automaker plans to send owners notification letters on Dec. 9 with additional details about the remedy.
Dive Insight:
The defective hardware involves the battery pack contactor, which may cause an internal solenoid to suddenly open due to a poor coil connection, according to the recall report. The solenoid acts as a high-voltage switch to power the vehicle’s drivetrain. The issue inhibits a driver from applying torque and accelerating, increasing the risk of a crash.
If the problem occurs while the vehicle is in motion, drivers will immediately receive a visual warning on the vehicle’s touchscreen display instructing them to safely pull over. But the condition can also occur when the vehicle is parked, preventing drivers from being able to shift into drive.
Tesla sourced the affected solenoids from Mexico-based Tier 2 electronics supplier InTiCa Sistemas Mecatrónicos. These solenoids were then installed in battery pack contactors manufactured by Taiwan-based Tier 1 supplier Song Chuan.
On Aug. 8, Tesla’s Field Reliability team began investigating incidents detailed in service records where vehicles were unable to shift from park to drive. Its investigators discovered high coil resistance in the battery pack contactors of the vehicles.
From August through September, Tesla investigators gathered and analyzed battery pack contactors from existing vehicles and conducted a detailed failure analysis, including a review of production and repair records.
Tesla completed its investigation in early October, and based on its findings, the automaker approved the voluntary recall on Oct. 3.
As of Oct. 7, Tesla has received 36 warranty claims and 26 field reports related to the battery hardware defect. But the company is not aware of any accidents or injuries.
According to the recall report, the faulty solenoids were part of a “fixed batch” of battery pack contactors manufactured by Song Chuan and installed in Tesla vehicles between March 8 and Aug. 15, 2025. The replacement contactor does not use an InTiCa solenoid and thus will maintain proper coil connection, the report said.
Many of Tesla’s prior recalls have historically been addressed with over-the-air software updates. But for this recall, owners will need to visit a Tesla Service Center in order to have the battery pack contactors replaced by technicians.
The repairs will be free, since all of the recalled vehicles are covered under warranty.
