For a long-time Tesla owner, returning his leased car turned into an expensive nightmare. His Tesla Model 3 Performance, which he received in 2020, had caused him no major problems over four years. But when he returned the vehicle to the leasing company Santander in July 2024, he was confronted with an unexpected and expensive surprise. TÜV Süd discovered a porous and cracked jack support, indicating a manufacturing defect. To make matters worse, the report revealed that the battery housing also needed to be replaced, which cost €13,700.
Dangerous production defect in the Tesla Model 3: Numerous cases uncovered – Important information for drivers
Unfortunately, this incident is not an isolated case. EFAHRER.com reported similar damage in 2022, but Tesla only repaired it superficially. The company minimized the problems and described the damage as minor. But these defects are serious: Especially in winter, the defective jack mounts can allow moisture to penetrate the battery area, which is potentially dangerous. It remains questionable whether the Model 3 can even be safely lifted onto a lift. A court ruling shows that the vehicle remains drivable despite the damage, but a visit to the workshop could be risky. In the event of an accident, emergency services might not be able to lift the car safely.
Tesla attorney Dr. Christoph Lindner confirmed that "numerous new cases of jacking up" have been reported, especially in vehicles returned from leased vehicles. TÜV Süd often acts as an expert in these cases. EFAHRER has received another report on a similar incident, also from TÜV Süd. Whether replacing the battery is actually necessary can only be conclusively determined through counter-reports from other testing centers.
Tesla remains silent on hidden production error: Drivers could face high costs
Despite growing criticism, Tesla remains reserved and has not yet issued an official statement on the allegations. However, in one 2021 case, an invoice stated: "The factory process was improved on April 26, 2021." Attorney Lindner interprets this as an indirect admission of a serial problem. It is believed that many affected vehicles are already on the road. This will become particularly problematic in 2024, when numerous lease returns of vehicles of these affected models are imminent. It is to be expected that Tesla could demand high remediation costs for which the drivers are not responsible.
In the 2021 legal dispute, Tesla was forced to fix the defects free of charge after lengthy discussions and a lawsuit. However, it is unlikely that the company will fix similar defects free of charge again in the future.
Tesla Leasing: How to protect yourself from hidden production defects and unexpected costs
Customers who leased their Model 3 in 2020 and 2021 and whose vehicles were produced in the US are particularly affected. Tesla attorney Dr. Christoph Lindner has some valuable advice for these affected customers. First, they should dispute the lessor's claims, disputing both the amount and the reason for the payment. It is also important to carefully document the damage and all correspondence.
Dr. Lindner recommends informing the lessor that the damage to the jack supports was already present at the factory. Hardly any lessee inspects the underbody of a new car upon delivery, so many of these hidden defects only become apparent later. The lawyer believes that lessees should not be liable for damage that was already present at the time of delivery. Furthermore, the lessor could assert a claim against Tesla Germany GmbH for intentional, immoral damage.
Finally, Lindner advises affected Tesla drivers with legal expenses insurance to seek legal assistance early on to avoid undesirable consequences such as Schufa entries. Future leasing customers are advised to thoroughly inspect the car—especially the underbody—upon delivery. Even if the problem has since been resolved, it's better to be safe than sorry. Legal expenses insurance can also be of great benefit in such cases.
