Tesla has finalized the remedy for the recent Cybertruck Off-Road Lightbar recall, introducing a bolt-on solution instead of the original adhesive-only installation.
The recall, issued last month due to reports that the lightbar could detach while driving, impacts thousands of Cybertrucks where the urethane adhesive may have been improperly primed. Tesla’s new service procedure (SB-25-90-001) addresses this by adding a physical anchoring mechanism to the system.
The Mechanical Fix
The solution involves a new set of brackets that secure the lightbar directly to the vehicle frame. According to the service bulletin, the new bracket bolts into the side of the existing lightbar and anchors it to the frame of the vehicle.
The procedure involves drilling a hole through the cosmetic roof appliques, as well as into the roof frame, which will then be resealed with a threaded rivet nut to hold the lightbar bracket in place. Tesla is not using the existing rooftop rack crossbar mounts like 3rd-party lightbars, as they are likely too far back to effectively exert pressure on the lightbar.
This new mechanical attachment method, as Tesla describes it, ensures that even if the adhesive were to fail completely, the lightbar would remain securely attached to the truck.
Recall & Installation Process
Tesla has outlined a two-tier approach for existing owners, depending on the state of the lightbar.
If the Lightbar is firmly attached: Tesla Service will not remove the unit. Instead, they will simply install the new brackets to the existing setup, acting as a permanent safety retention system.
If the Lightbar is loose: Tesla Service will fully remove the unit. Old adhesive will be cleaned and removed, and replaced with high-strength VHB tape. Finally, the new brackets will be installed to secure it.
Moving forward, all new lightbar installations will default to this second method, utilizing both the VHB tape for flush mounting and the roof-bolted brackets for mechanical security.
This solution reverses the original primer-and-urethane process that triggered the initial recall, offering a more secure installation method for the Cybertruck’s unique lightbar accessory.
