Tesla Recalls 13,000 Model Y And Model 3 EVs Over Battery Defect That Causes Sudden Power Loss

Tesla is recalling nearly 13,000 Model Y and Model 3 electric vehicles due to a battery pack defect that could cause sudden loss of propulsion while driving, according to the National Highway Traffic Safety Administration. The recall affects 7,925 Model Y vehicles from the 2026 model year and 5,038 Model 3 sedans from the 2025 model year, all manufactured between March and August 2025.

This hardware recall requiring physical repairs comes at a challenging time for Tesla, which just launched cheaper “Standard” trim versions of both models in early October to attract budget-conscious buyers after the $7,500 federal EV tax credit expired on September 30. Unlike Tesla’s typical over-the-air software fixes, affected owners must visit service centers for a one-hour repair.

Battery Contactor Defect Creates Crash Risk

The recalled vehicles contain a faulty battery pack contactor manufactured with an InTiCa solenoid that may suddenly open due to a poor coil termination connection. Tesla’s official recall notice explains that “if one or both contactors open when the vehicle is in drive, the driver loses the ability to apply torque to the vehicle using the accelerator pedal resulting in a loss of propulsion, which may increase the risk of a collision.”

Contactors function as high-voltage switches connecting the battery pack to the vehicle’s electric motors. When this connection fails, drivers lose all acceleration capability instantly—a potentially dangerous situation on highways or in heavy traffic. However, power-assisted braking and steering remain functional even if the contactor opens.

As of October 7, 2025, Tesla had identified 36 warranty claims and 26 field reports related to the contactor issue, according to NHTSA documents. The company stated it is not aware of any collisions, injuries, or fatalities caused by the defect.

Cybertruck Gets Quick Software Fix For Overly Bright Lights

Tesla also recalled 63,619 Cybertrucks this week for a separate lighting issue—but this one received the company’s signature over-the-air fix. The recall addresses front parking lights that shine brighter than federal safety standards allow, potentially distracting oncoming drivers and increasing crash risk.

The Cybertruck recall affects 2024-2026 model year vehicles manufactured between November 13, 2023, and October 11, 2025, with software versions prior to 2025.38.3. Tesla discovered the issue during internal testing on October 1 and deployed a free software update within days. The NHTSA confirmed Tesla is not aware of any collisions, injuries, or fatalities related to the lighting issue.

The contrast between the two recalls is stark: Cybertruck owners simply install a software update at home, while Model 3 and Model Y owners must schedule service appointments and wait for physical repairs.

Repair Process And Timeline For Affected Owners

Tesla will replace the faulty battery pack contactors free of charge with certified components that don’t contain InTiCa solenoids. The repair takes approximately one hour to complete at authorized service centers.

Owner notification letters are expected to be mailed by December 9, 2025. However, concerned owners can check if their vehicle is affected immediately using either Tesla’s VIN Recall Search tool or the NHTSA VIN Recall Search at NHTSA.gov/recalls.

To schedule the repair, owners should use the Tesla app by selecting Service > Request Service > Other > Something Else, then entering “Open Recall Repair – Battery Pack Contactors” in the description field. The NHTSA recall campaign number is 25V690 for reference.

Tesla’s Quality Control Under Scrutiny As Standard Trims Launch

The timing of this recall adds pressure on Tesla as it tries to maintain sales momentum following the federal tax credit expiration. The company unveiled Model Y Standard at $41,630 and Model 3 Standard at $38,630 in early October—offering $5,000 savings compared to Premium trims by eliminating features like panoramic glass roofs, heated rear seats, and Autosteer capability.

These stripped-down models were designed to fill the affordability gap left by the expired $7,500 tax credit, but a recall affecting recently manufactured vehicles undermines confidence in Tesla’s production quality. The company has faced multiple recalls throughout 2025, including a 46,000-unit Cybertruck recall in March for detaching windshield trim and ongoing federal investigations into its Full Self-Driving software.

Tesla reported its fourth consecutive quarterly profit decline on October 23, with third-quarter earnings plunging 37% to $1.4 billion. While revenue rose thanks to customers rushing to claim the tax credit before expiration, analysts worry this pulled forward demand from the current quarter.

EVXL’s Take

Tesla’s latest recall exposes a fundamental tension in its production strategy: can the company scale quickly enough to meet aggressive pricing targets without sacrificing the quality control that made it an industry leader? This isn’t a software glitch Tesla can patch overnight—it’s a hardware manufacturing defect requiring 13,000 individual service appointments.

We’ve documented Tesla’s recall history extensively at EVXL, from the Cybertruck’s sticky accelerator pedal to multiple Autopilot investigations. What stands out about this battery contactor issue is the supplier component failure. The InTiCa solenoid represents the kind of third-party manufacturing variance that can slip through even rigorous quality checks, especially when production is ramped up to hit volume targets. BMW faced a similar power loss recall earlier this year affecting over 70,000 EVs, showing this isn’t just a Tesla problem—it’s an industry-wide challenge as automakers scale EV production.

The broader question is whether Tesla’s rush to launch cheaper Standard trims immediately after losing the tax credit has stressed its quality control systems. These recalled vehicles were built during the same March-August 2025 period when Tesla was finalizing the Standard trim designs and preparing for their October launch. Coincidence? Maybe. But it’s worth noting that only about 1% of recalled vehicles actually have the defect—suggesting the real issue is identifying which units contain the faulty parts.

For potential buyers eyeing those new $38,000-$41,000 Standard trims, this recall shouldn’t necessarily be a dealbreaker. Tesla’s handling it responsibly with free repairs and proactive NHTSA notification. But it does highlight that cheaper doesn’t always mean simpler, and even “basic” EVs rely on complex high-voltage systems where quality matters more than creature comforts.

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