Failed Rear Lower Control Arm / Service Bulletin SB-19-31-001

[Richard S 85]

And now it's my turn to be added to a/the list Backing out of my driveway last Friday, the rear driver's side control arm failed with me completely blocking the side street. Fortunately, the two drivers showed up relatively quickly and people were understanding (and we have multiple exits from our neighborhood). The tow drivers were kind enough to help keep the rear lifted while unloading so I could leave the car on jack stands and have a prayer of repairing it myself. My car is a 2015 85D with just ~ 69,400 miles.

Tesla quoted the following parts just based on the photos I sent through the app:

BOLT HF M12X1.75X70 [10.9]-U-G720(2007078), 1x @ $17
NUT,HF,M12X1.75, [10],ZNNI,PTM. (1111545-00-A), 1x @ $0.32
BOLT HF M12X75 PC109(1043053-00-A, 1x @ $2.38
REAR UPPER LINK SUSPENSION ASSEMBLY - DUAL MOTOR(1027426-00-C), 1x @ $230.00
RR SUSP LCA ASSY(1021416-00-D), 1x @ $350.00

Original quote included labor, but I don't feel like paying for the hour long tow, plus coordinating transport to/from to pick the car up once it was done. Can't order the parts for shipping either, at least not through the service center*. I found it surprisingly difficult to find the lower control arm assembly aftermarket, but can find nearly every other component. Did locate one at EVAnnex for $250, and I have that on order. I'll be doing my best to repair solo - of course it's getting into the cold, wet, winter season! Yippee! Fingers crossed that the lower control arm assembly is the only busted part. Everything else looks surprisingly good.

Side note: First AAA tow driver showed up in < 5 minutes, but hadn't looked at the ticket, only that there was an emergency request in his area. As soon as he pulled up and saw it was a Tesla, he noped right out and called in backup.

* Tesla did tell me I could register to order the parts myself, but registration requires submitting photos of my "facility" and choosing what type of retail establishment I am. Didn't seem worth it, especially with a 5-7 day process for a maybe approval just to pay more for the part.

Welcome to the list . I hope this growing list will assist with the truth finding function of potential litigation by helping to establish a pattern of failures.

 

[Newscutter]

Scroll up to Post #145 Failed Rear Lower Control Arm / Service Bulletin SB-19-31-001 in this thread

Interestingly, I didn't find any instructions but I DID find that they stole my intellectual property-- a picture from a blog post in 2014-- cropped my attribution and altered it.

I wonder if I could get them to cover my parts costs in lieu of a slam dunk plagerism lawsuit?

At the very least, it tells me a lot about a company when they can't EVEN ASK. But I digress...

I will be publishing more pictures and videos of my long-completed replacements soon enough, so maybe they can steal those too.

The short answer to my original question is: yes, you need a flex head ratcheting 18mm wrench (spanner). It's the only way to get the captive nut on and off.

 

[cleverscreenam]

Dude, you're upset that they copied a picture of how to use a floor jack to lift a car? Seriously? Like, did you even invent said jack, or said car, or said hockey puck? And how much money did you plan to make off that picture in the art world? I mean if it were my picture I'd be honored, the company is doing great work in a niche market that sorely needed solutions.

Anyways, I've got that jack, and that puck, and that car, so if truly bothers you I'll go outside and jack the car up, snap a pic, email it to N2itive, and sign away the rights to the picture so it can replace yours...
Lawyers

 

[tekknoschtev]

Update: I'm back in business! Or at least, I'm driving again. Ordered from evannex.com Tuesday evening and got a surprise when the lower control arm arrived mid-day today. WFH gave me the flexibility to take advantage of the limited sunlight in Michigan afternoons during the winter. Less than 2 hours later, everything was buttoned back up and I was back inside thawing my fingers and toes.

Fortunately for me, it seems as though the lower control arm is the only thing that failed. I'm going to setup an appointment for an alignment soon. For peace of mind, given how (relatively) simple the repair was, when it's a bit warmer I'm likely going to order another to replace the passenger-side part. It's a lot less hassle to replace on my terms than to have to get a tow back into my own driveway.

 

[Alabaster]

I just recently changed the front aft bar links before they broke as they were original. Now I am seeing this and guessing the rear need replaces. Are the rear similar to repair (more or less difficult)?

 

[Newscutter]

Dude, you're upset that they copied a picture of how to use a floor jack to lift a car?

Anyways, I've got that jack, and that puck, and that car, so if truly bothers you I'll go outside and jack the car up, snap a pic, email it to N2itive, and sign away the rights to the picture so it can replace yours...

Yeah, it bothers me. I guess I'm old fashioned in that ASKING doesn't seem like a big deal when theft is the alternative. The worker is due their wages or at least a freaking courtesy if they can't extend the actual courtesy of asking.

But I don't do this stuff for the community to get money or the respect of m'dude above. I do it because I think helping people is ultimately more important and I don't see any other DIY videos on how to replace these parts.

So here's how I did it-- and I strongly, STRONGLY recommend you do not get salvage/used parts because they have revised them to (hopefully) mitigate further failures.

 

[Newscutter]

Another local owner I know just had his fail. We'll see if the service center changes their tune as his is ALSO outside the TSB production dates but shares the same failed part. I also urged him to make a safety complaint report to NHTSA.

Meanwhile -- I ran across this, which was filed in November 2020, but was decided in favor of Tesla last month (WTH!??) :

Williams v. Tesla, Inc. (4:20-cv-08208), California Northern District Court

Williams v. Tesla, Inc. (4:20-cv-08208), California Northern District Court, Filed: 11/20/2020

www.pacermonitor.com

‘Gambling with Lives’: Tesla Model S, Model X Vehicles Plagued by Suspension Defects, Class Action Alleges

Tesla Model S and Model X vehicles manufactured between September 2013 and October 2018 are plagued by at least one latent defect that can cause front and rear suspension control arm assembly components to prematurely loosen, wear, crack and/or break.

www.classaction.org

Here's a link to download a PDF of the lawsuit (also attached here): https://www.classaction.org/media/williams-v-tesla-inc.pdf

 

[Psilver]

Here is the latest update on my situation. After having repaired what was broken (so they replaced the broken left lower control arm, replaced preemptively the right side, replaced a bunch of suspension related things that were also broken, not sure if those broke because the control arm failed), I decided to write an email to a Tesla manager/director. I got that email back in 2016 and I've kept it ever since. I've used it twice and each time, the person always got back to me. So I thought I could write again and see what happens.

In my email, I described what happened in details and I voiced my concerns about security as well as what I thought was a poor engineering of that component. I made sure to stay polite and constructive and in the end, I asked why this could not be part of a recall for the early Model S generations.

It only took a day before I got a call from the Montreal service center. We talked for a good half hour and the manager said that he would try to do something for me. A couple of days later, he called me back with a 100$ credit to my account to thank me for taking the time I took to write that email and described what happened. He then reimbursed a little more than 1500$ (25% of the bill). That 1500$ plus 100$ plus 800$ that I got off when I did the repairs almost cover the cost of replacing the lower control arms.

All in all, I wished this would be part of a recall, but at least I managed to bring the costs down a little. I'm glad I reached out to that director. Funny enough, a friend of mine sent me a picture of a Model S at a service in Ottawa where that S seemed to also be suffering from a broken control arm.

So if it happens to you, don't be scared to escalate this. Originally the guy at the service center said he could not escalate my case and going to court would be my only option, even though I told him I would reach out to this director. I'll see if I send a similar email to Transport Canada...

My white 2016 Model S rear LH control arm also failed this week and service is quoting nearly 10K to replace both lower control arms in the rear and uppers in the front.

 

[Psilver]

Here is the latest update on my situation. After having repaired what was broken (so they replaced the broken left lower control arm, replaced preemptively the right side, replaced a bunch of suspension related things that were also broken, not sure if those broke because the control arm failed), I decided to write an email to a Tesla manager/director. I got that email back in 2016 and I've kept it ever since. I've used it twice and each time, the person always got back to me. So I thought I could write again and see what happens.

In my email, I described what happened in details and I voiced my concerns about security as well as what I thought was a poor engineering of that component. I made sure to stay polite and constructive and in the end, I asked why this could not be part of a recall for the early Model S generations.

It only took a day before I got a call from the Montreal service center. We talked for a good half hour and the manager said that he would try to do something for me. A couple of days later, he called me back with a 100$ credit to my account to thank me for taking the time I took to write that email and described what happened. He then reimbursed a little more than 1500$ (25% of the bill). That 1500$ plus 100$ plus 800$ that I got off when I did the repairs almost cover the cost of replacing the lower control arms.

All in all, I wished this would be part of a recall, but at least I managed to bring the costs down a little. I'm glad I reached out to that director. Funny enough, a friend of mine sent me a picture of a Model S at a service in Ottawa where that S seemed to also be suffering from a broken control arm.

So if it happens to you, don't be scared to escalate this. Originally the guy at the service center said he could not escalate my case and going to court would be my only option, even though I told him I would reach out to this director. I'll see if I send a similar email to Transport Canada...

Any chance I can private message you for some advice?

 

[tm1v2]

@Psilver What's your warranty situation? Is your car clearly out of warranty coverage for suspension?

From your location I assume that's $10k CAD which works out to $7.4k USD. (That's just from exchange rate, I don't know how Canadian pricing for auto parts and labor tends to compare.)

Post the estimate/invoice parts and labor list so we can understand exactly what they're quoting you for.

 

[Psilver]

out of warranty. the estimate is to replace the lower LH and RH arms and the upper LH and RH arms (as they save some give); and the arm that broke caused some additional damage to springs halfshat etc that also needed replacing.

Performed suspension inspection. Replaced LH Front Upper Control Arm. Replaced RH Front Upper Control Arm. Replaced LH Aft Lower Front Suspension Link. Replaced RH Aft Lower Front Suspension Link. Replaced Left/Right Front Lower Fore Links. Replaced LH Lower Rear Control Arm Assembly. Replaced RH Lower Rear Control Arm Assembly. Replaced LH Upper Rear Suspension Link. Replaced RH Upper Rear Suspension Link. Replaced Rear LH Rear Toe Link Assembly. Replaced LH Rear Integral Link. Replaced LH Rear Halfshaft Assembly. Replaced LH Rear Spring and Damper Assembly. Performed brake service. Performed 4 wheel alignment.

Correction: General Diagnosis
Correction: Control Arm - Upper - Front - LH
Price Adjustment
210.00 0.00
Price Adjustment
176.40 0.00
Price Adjustment
350.00 0.00
6.00 0.00
0.70 0.00 1.10 0.00
Subtotal
210.00
Subtotal
176.40
Subtotal
350.00 6.00 0.70
1.10
(2nd Generation) (Remove & Replace) Remove and Replace
Parts Replaced or Added
Part Quantity
FR UPR CTRL ARM, 1.00 LEFT HAND, DUAL MOTOR(1043965-00-B)
BLT HF M10X1.50X100 2.00 [10.9] DP ZNAL-
W(1004357-00-A)
NUT HF M10X1.50 [10] 1.00 ZNAL-W(1004351-00-A)
BLT BTNHD 1.00 M10X1.50X57 [10.9] ZNAL-W(1004350-00-A)
-
Unit Price
350.00 3.00 0.70
1.10
Parts Subtotal 357.80
1 of 6

Correction: Control Arm - Upper - Front - RH
Price
Adjustment Subtotal
(2nd Generation) (Remove & Replace) Remove and Replace
Parts Replaced or Added
Part Quantity
FR UPR CTRL ARM, 1.00 RH, DUAL
MOTOR(1043966-00-B)
BLT HF M10X1.50X100 2.00 [10.9] DP ZNAL-
W(1004357-00-A)
NUT HF M10X1.50 [10] 1.00 ZNAL-W(1004351-00-A)
BLT BTNHD 1.00 M10X1.50X57 [10.9] ZNAL-W(1004350-00-A)
-
Correction: Link - Front Suspension - Lower - Aft - LH (Remove & Replace) - Remove and Replace
Price
100.80
Parts Replaced or Added
Part Quantity
WASHER, NORDLOCK, 1.00 15.2X30.7X3.4(1033093-
00-A)
FR SUSP AFT LINK 1.00 ASSY(1027351-00-E)
NUT HF M14X1.50 [10] 1.00 ZNNI NL
INSERT(1004358-00-C)
Unit Price
3.15
330.00 0.70
Price
3.15
330.00 0.70
Correction: Link - Front Suspension - Lower - Aft - RH (Remove & Replace) - Remove and Replace
Price Adjustment
100.80 0.00
Price Adjustment
3.15 0.00
330.00 0.00 0.70 0.00
Subtotal
100.80
Subtotal
3.15
330.00 0.70
Parts Replaced or Added Part
WASHER, NORDLOCK, 15.2X30.7X3.4(1033093- 00-A)
FR SUSP AFT LINK ASSY(1027351-00-E)
NUT HF M14X1.50 [10] ZNNI NL INSERT(1004358-00-C)
Quantity
1.00
1.00 1.00
Unit Price
3.15
330.00 0.70
Correction: Links - Fore - Lower - Front - LH/RH (Remove & Replace) - Remove and Replace
Price
Parts Subtotal 333.85 Adjustment Subtotal
Unit Price
350.00 3.00 0.70
1.10
176.40
Price
350.00 6.00 0.70
1.10
0.00 176.40
Adjustment Subtotal
0.00 350.00 0.00 6.00
0.00 0.70 0.00 1.10
Parts Subtotal 357.80 Adjustment Subtotal
0.00 100.80
Adjustment Subtotal
0.00 3.15
0.00 330.00 0.00 0.70
Parts Subtotal 333.85
151.20
0.00 151.20
2 of 6

Parts Replaced or Added
Part Quantity
Unit Price
255.00 290.00 3.15 0.70
Price Adjustment
255.00 0.00 290.00 0.00 6.30 0.00 1.40 0.00
Subtotal
255.00 290.00 6.30 1.40
FORE LINK ASSEMBLY, RIGHT HAND(1420346- 00-C)
FORE LINK ASSEMBLY, LEFT HAND(1420341- 00-C)
WASHER, NORDLOCK, 15.2X30.7X3.4(1033093- 00-A)
NUT HF M14X1.50 [10] ZNNI NL INSERT(1004358-00-C)
1.00 1.00 2.00 2.00
Correction: Control Arm Assembly - Rear - Lower - LH (Remove & Replace) - Remove and Replace
Price Adjustment
176.40 0.00
Price Adjustment
500.00 0.00
Subtotal
176.40
Subtotal
500.00
Parts Replaced or Added
Part Quantity
RR SUSP LCA 1.00 ASSY(1021416-00-D)
Unit Price
500.00
Correction: Control Arm Assembly - Rear - Lower - RH (Remove & Replace) - Remove and Replace
Price Adjustment
176.40 0.00
Price Adjustment
500.00 0.00
Subtotal
176.40
Subtotal
500.00
Parts Replaced or Added Part
RR SUSP LCA ASSY(1021416-00-D)
Quantity
1.00
Unit Price
500.00
Correction: Link - Suspension - Rear - Upper - LH (Remove and Replace) - Remove and Replace
Price Adjustment
189.00 0.00
Price Adjustment
3.00 0.00 0.35 0.00
3.30 0.00 285.00 0.00
Subtotal
189.00
Subtotal
3.00 0.35
3.30 285.00
Parts Replaced or Added
Part Quantity
BOLT HF M12X1.75X70 1.00 [10.9]-U-G720(2007078)
NUT,HF,M12X1.75, 1.00 [10],ZNNI,PTM.
(1111545-00-A)
Unit Price
3.00 0.35
3.30 285.00
BOLT HF M12X75 PC109(1043053-00-A)
REAR UPPER LINK SUSPENSION ASSEMBLY - DUAL MOTOR(1027426-00-C)
1.00 1.00
Parts Subtotal 552.70
Parts Subtotal 500.00
Parts Subtotal 500.00
Parts Subtotal 291.65
3 of 6

Correction: Link - Suspension - Rear - Upper - RH (Remove & Replace) - Remove and Replace
Price
189.00
Price
285.00
Price
226.80
Price
115.00
Price
315.00
Price
115.00
Price
453.60
Price
4.40 650.00
Price
239.40
Price
Adjustment Subtotal
Parts Replaced or Added
Part Quantity
REAR UPPER LINK 1.00 SUSPENSION
ASSEMBLY - DUAL MOTOR(1027426-00-C)
Unit Price
285.00
0.00
Adjustment
0.00
189.00
Subtotal
285.00
Correction: Toe Link Assembly - Rear - LH - 2nd Generation Rear Node (Remove & Replace) - Remove and Replace
Parts Subtotal 285.00 Adjustment Subtotal
Parts Replaced or Added
Part Quantity
REAR TOE LINK, X- 1.00 AXIS(1043964-00-C)
Unit Price
115.00
0.00
Adjustment
0.00
226.80
Subtotal
115.00
Correction: Integral Link - Rear - LH (Remove & Replace) - Remove and Replace
Parts Subtotal 115.00 Adjustment Subtotal
Parts Replaced or Added
Part Quantity
RR SUSP INTEGRAL 1.00 LINK ASSY PERF PLUS(1021422-00-B)
Unit Price
115.00
0.00
Adjustment
0.00
315.00
Subtotal
115.00
Correction: Halfshaft - Rear Drive Unit - LH (Remove & Replace) - Remove and Replace
Adjustment
0.00
Adjustment
0.00 0.00
Subtotal
453.60
Subtotal
4.40 650.00
Parts Replaced or Added
Part Quantity
WASHER SAFETY 1.00 M24X39(1020296-00-B)
REAR HALF SHAFT 36 1.00 MM(1007719-00-C)
Unit Price
4.40 650.00
Correction: Spring and Damper Assembly - Rear - LH (Remove & Replace) - Remove and Replace
Parts Subtotal 654.40 Adjustment Subtotal
Parts Replaced or Added Part
REAR COIL SPRING MODULE - DM S3(1015620-03-D)
Quantity Unit Price
1.00 1,135.00
0.00
Adjustment
239.40
Subtotal
1,135.00
1,135.00
0.00
Parts Subtotal 115.00
4 of 6
Correction: Four Wheel Alignment Check and Adjust
Parts Subtotal 1,135.00 Price Adjustment Subtotal 330.00 0.00 330.00 Pay Type: Customer Pay
Total Parts Amount Total Labor Amount
5,532.05 3,211.20

 

[Psilver]

@Psilver What's your warranty situation? Is your car clearly out of warranty coverage for suspension?

From your location I assume that's $10k CAD which works out to $7.4k USD. (That's just from exchange rate, I don't know how Canadian pricing for auto parts and labor tends to compare.)

Post the estimate/invoice parts and labor list so we can understand exactly what they're quoting you for.

see above

 

[KalJoMoS]

Can’t you make a screenshot of that file or attach available PDF file?

 

[Dennis Nilsson]

You can get low mileage control arms from ebay for under $200 easily. It's the same part left and right.

The toe and camber links are about $100 each, new from Teala.

They are very simple to replace, any shop can do it. Or even by yourself if you have the tools. So whatever you do, don't go for the quoted $4000 Tesla offer.

My 2013 P85+ probably is manufactured after July, so it's possibly affected.. I'm just about to replace the toe links because of failed bushings, have to check the part number of control arms as well. I assume if they are 1027459-99-A they are already changed?

This is the best answear that I have read!!! So mutch headake just because they OVERCHARGE a know problem. Thanks for you´re post! ( I have the exact same problem with my MS-16, the righthand side just cracked and destroyed the airsuspension, I got it lifted from the ground and delivered to the dealer were I bought the car 1-2 months ago, they did they right thing= they take the righthand side and I pay for the lefthand side that is not broken just yet. It saved me 25k Sek and I pay 5k Sek for everthing.).

 

[chrisgla]

2016 MS P90D, only 39,000 miles. Tesla have invoiced me multiple times for diagnostics for "suspension noise over bump" including twice this year, most recently around 2,000 miles ago. I really struggle to see how they didn't find this when they done the other "routine" fix on the dodgy CV/ half shafts a few months ago. I finally put the car on stands myself, loosened the front lower fore arm and the ball joint fell out when I loosened the nut.
Tesla is over $2,000 just for parts on the front.
At least I caught it in time

 

[JWest412]

I just took my 2016 MX 90d in for new tires yesterday and they tried to invoice me for $3,000 as they found the rear control arms needed replacing. They sent a video of the tech wiggling the tightened wheel slightly back and forth. I didn’t have them do the repair but because they put all the part numbers on the quote, I can order them and do it myself. Anyone do this yet?

 

[KalJoMoS]

There are several reports here pointing that if you can avoid the disaster by preventive action then the change is straight forward and quite cheap. Just dismount old part and mount new. I can’t say for sure does the car needs then a wheel alignment as of it? What was the content of that estimate?

 

[KalJoMoS]

Found this detailed post if anyone is interested to get hands on…

 

[PaulF2020]

Guys, are only older revisions of this arm affected or anyone experienced failure on latest revision too?

Also, I'm not sure if Delphi parts available in the US, but here is the video from them, which shows exactly how to replace it:

 

[maximizese]

Yikes, so it's not just the rear control arm but the front fore and aft links too? I've got 134Kmiles/10yrs on the car right now am considering preemptively replacing them as I'd hate to have these fail while my wife is driving the car.