Tesla Addresses 'Cell Dent' Issues in Cybertruck Batteries, Sends Units Back to Gigafactory Texas

Tesla has discovered cell dent problems in its Cybertruck battery packs, prompting the automaker to send affected vehicles back to Gigafactory Texas for replacement. The issue affects inventory vehicles and highlights challenges as Tesla ramps up production of its highly anticipated electric pickup.

Smooth Cybertruck Production Faces Challenges

The manufacturing ramp for Cybertruck has been rather smooth, and it has been in production for a year now. Gigafactory Texas has increased Tesla's Cybertruck production capacity to several thousand units per week.

The vehicle program, meanwhile, does have its flaws.

Many owners have reported many repair visits, and Tesla has issued multiple recalls on the Cybertruck. In fact, Tesla repurchased a number of Cybertrucks that had experienced numerous issues.

Tesla Investigates Cell Dent Issues in Cybertruck Batteries

Electrek has just discovered a new issue with Cybertrucks: cell dings.

Documents examined by Electrek and persons with knowledge of the situation indicate that Tesla has found "cell dents" in the battery packs of certain Cybertrucks and is currently returning them to Gigafactory Texas to get new ones.

Only the Cybertruck, a vehicle exclusively manufactured by Tesla, uses the company's proprietary 4680 battery cell.

A source close to the situation said that the problem had been found in "many inventory vehicles," but that customers' vehicles had not yet been affected.

Tesla Adjusts Cybertruck Inventory for U.S. and Canada Markets

After being trapped with an excessive amount of Cybertrucks in inventory in the US, Tesla has taken action, such as homologating more than 800 Cybertrucks in inventory from the US for the Canadian market and converting Foundation Series Cybertrucks into ordinary ones.

These updates, along with others, such as the replacement of older cars' computers with self-driving technology, are already putting a strain on Tesla's service and repair centers.

Battery Harness Issues Add to Tesla’s Challenges

Cybertrucks with faulty battery packs are thus being sent to less congested sites, including as Gigafactory Texas, by the carmaker.

It is unknown how many vehicles are impacted by this "cell dent" problem, and Tesla has not released a service bulletin about the matter.

Nevertheless, Tesla has just discovered a further problem with the Cybertruck battery pack and has issued a service notice regarding it. The battery auxiliary harness is placed incorrectly in some trucks.

The carmaker penned:

“On certain Cybertruck vehicles, the HV battery ancillary harness may have been improperly routed, which might strain the harness branches and/or connectors between the High Voltage Controller (HVC) and Battery Management Boards (BMBs), potentially preventing HVC and BMB communication through one of the two harness branches.”

It is recommended that Tesla technicians check vehicles for any symptoms and, if needed, repair the harness on trucks that are going into duty.