Tesla, Inc. has issued a recall for 294 Model S and Model X vehicles from the 2024 and 2025 model years due to a potential defect in the driver airbag that could increase the risk of injury during a crash, according to documents filed with the National Highway Traffic Safety Administration (NHTSA).
The recall, identified as NHTSA Recall No. 24V-967, affects vehicles manufactured between November 6, 2024, and November 27, 2024. Tesla’s internal designation for the recall is SB-24-20-001.
The issue stems from damage to the driver airbag during the supplier’s assembly process. If the airbag contains a deep fold or is improperly positioned near the heat diffuser, it may tear upon deployment, failing to perform as designed.
The supplier responsible, ZF-Lifetec, located in Chihuahua, Mexico, attributed the defect to the use of an unauthorized tool during assembly.
“An airbag that tears during deployment may not provide adequate crash protection, increasing the risk of injury,” the recall notice stated.
Investigation and Remedy
The defect was discovered on November 3, 2024, during routine lot testing at the supplier’s facility. Following the identification of the issue, ZF-Lifetec halted shipments and began an internal investigation.
By December 16, 2024, Tesla opted to voluntarily recall the affected vehicles, despite no known warranty claims, accidents, injuries, or fatalities linked to the defect.
Tesla plans to replace the faulty airbag modules at no cost to customers. The replacement airbags have been certified and meet Tesla’s safety standards.
Since all affected vehicles remain under warranty, Tesla will not provide pre-notice reimbursement for any repairs made prior to the recall.
Tesla also reported that the supplier removed the unauthorized tool from the production line on November 16, 2024. Personnel were retrained, and the assembly process was updated to prevent further deviations.
ZF-Lifetec has committed to ongoing quality audits and monthly training workshops to ensure compliance.
Recall Schedule
Tesla will notify all its stores and service centers by December 26, 2024. Owners of the affected Model S and Model X vehicles will receive notification letters by February 21, 2025.
Customers with concerns are encouraged to contact Tesla service centers or visit the NHTSA website for further details.