Tesla Car Parts UK - Quality Used & Genuine Parts

How to Replace Tesla Headlights

Tesla headlight replacement is straightforward on most models thanks to accessible design. Whether replacing standard LED units or upgrading headlights on Model 3, Model Y, Model S, or Model X, the process follows similar principles across the range.

Step-by-Step Instructions:

1. Open the frunk (front trunk) and secure it safely. Locate the rear of the headlight assembly from within the frunk area. On Model 3 and Model Y, access is excellent with minimal obstruction. On Model S and Model X, the frunk provides good clearance to headlight mountings despite larger battery packs underneath.
2. Disconnect the electrical connector. Tesla headlights typically have a single main electrical connector for the LED headlight assembly. Press the release tab on the connector carefully and pull straight out without forcing. The connector is usually easily accessible from the rear of the headlight unit.
3. Remove the headlight mounting screws. Most Tesla models use T20 or T25 Torx screws to secure the headlight assembly. On Model 3 and Model Y, there are typically 3-4 screws along the top and side edges that are easily visible once the frunk is open. On Model S and Model X, expect similar mounting arrangements with clear access from above. Remove all mounting screws completely and keep them organized.
4. Release any additional clips or retainers. Some Tesla headlights use supplementary plastic clips for additional security. Gently pull the headlight forward slightly to check if any clips are holding it in place. Tesla clips are generally well-designed and release with steady pressure without excessive force.
5. Carefully remove the headlight assembly. With all screws removed and clips released, gently pull the headlight straight forward out of its mounting position. Tesla headlights are reasonably lightweight and manageable for one person. Support the unit as you pull to prevent it dropping and damaging the lens or paintwork.
6. Install the new headlight assembly. Reverse the removal process by aligning the new headlight with mounting points and push firmly into place ensuring all locating pins engage correctly. Refit all mounting screws and tighten securely. Reconnect the electrical connection ensuring it clicks firmly. Test all lighting functions before closing the frunk including low beam, high beam, indicators, and daytime running lights.

Important Notes: Tesla headlights use LED technology as standard across all models providing excellent longevity and brightness. When handling new headlights, never touch the lens surface. Tesla's over-the-air software updates may require headlight calibration after replacement, which can be done through the vehicle's touchscreen settings. Always check headlight alignment after fitting to ensure optimal visibility.

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How to Replace Tesla Front Bumper

Replacing a Tesla front bumper can be completed in 60-90 minutes with proper tools. This process covers Model 3, Model Y, Model S, and Model X, though specific mounting locations vary between models.

Step-by-Step Instructions:

1. Open the frunk and secure it safely. Locate the upper bumper mounting fixings along the top edge of the bumper assembly. Most Tesla models have 6-8 Torx screws or plastic clips securing the bumper to the upper mounting points. On Model 3 and Model Y, these are typically T25 Torx screws easily visible. On Model S and Model X, expect similar arrangements with accessible fixings from the frunk area.
2. Access the wheel arch areas on both sides. Turn the steering wheel fully to one side to maximize access to the wheel arch liner. Remove or release 3-5 plastic clips or screws securing the front section of the arch liner to expose side bumper mounting points. Tesla uses push-in plastic clips that release by pressing the center pin first. Repeat on both sides ensuring even access.
3. Remove the side mounting screws from both wheel arches. Behind each wheel arch liner, locate 2-4 screws or clips securing each side of the bumper. These are usually T25 or T30 Torx screws on Tesla models. Remove all side fixings carefully on both driver and passenger sides. Keep track of which fixings came from which location.
4. Remove undertray screws and lower bumper fixings. Get underneath the vehicle safely using ramps or jack stands. Locate and remove screws and clips securing any undertray panels and the lower edge of the bumper. Tesla typically uses 8-12 fixings along the bottom depending on model. Work systematically to ensure all lower fixings are completely removed.
5. Disconnect sensors, cameras, and electrical connections. Reach behind the bumper and disconnect all electrical connectors including front parking sensors (usually 4-6 sensors across the bumper width), front-facing camera for Autopilot if equipped in the bumper, and any additional connections for radar or other sensors. Press release tabs carefully and pull straight out. Count connections to ensure all are reconnected during refitting.
6. Release the bumper side clips and mounting tabs. Tesla bumpers are secured by plastic clips on each side that slot into the wing panels. With all fixings removed, firmly but gently pull the bumper forward from one corner while supporting the opposite side. You may need to wiggle slightly to release the clips. Listen for clicks as clips disengage indicating they've released properly.
7. Remove the bumper completely from the vehicle. With all fixings removed and clips released, carefully pull the bumper straight forward away from the vehicle in a controlled motion. Tesla bumpers are reasonably lightweight and manageable for one person on Model 3 and Model Y, though Model S and Model X benefit from a second person due to larger bumper size. Place on a protected surface to avoid scratching.
8. Prepare and fit the replacement bumper assembly. Transfer any sensors, brackets, or trim pieces from the old bumper if not fitted to your replacement. Align the new bumper with mounting points and push firmly into place ensuring all side clips engage properly with audible clicks. Reconnect all electrical connections including parking sensors in correct positions and cameras ensuring proper alignment. Systematically secure with all screws and clips in reverse order. Test all electrical functions including parking sensors beeping at correct distances and cameras displaying properly on the touchscreen before final assembly.

Top Tips: Tesla bumpers contain sensitive Autopilot sensors and cameras that require careful handling. When refitting parking sensors, ensure each clicks firmly and sits flush with the bumper surface as misalignment causes false warnings. Front-facing cameras and radar units may require recalibration through the Tesla touchscreen after bumper replacement to ensure Autopilot functions correctly. Check all panel gaps are even on both sides before final tightening. Tesla's precise manufacturing tolerances mean replacement parts typically fit well without extensive adjustment.

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Common Tesla Parts Problems & Solutions

Tesla vehicles are known for innovation, performance, and cutting-edge electric technology. The brand made a remarkable turnaround in reliability, ranking 9th out of 26 brands in the 2025 Consumer Reports reliability rankings, up dramatically from 17th in 2024 and 27th out of 28 brands in 2022. Tesla also ranked 5th in maintenance and repair costs and 4th in owner satisfaction. However, certain components can experience specific issues. Here are the most commonly reported Tesla parts problems based on verified data from UK owners, mechanics, and industry specialists.

Suspension Control Arm Failures (Model S, Model X, Model 3, Model Y) - Critical Issue:

• Control Arm Premature Failure: Suspension control arm failures represent Tesla's most serious reliability concern affecting Model S, Model X, Model 3, and Model Y. Front and rear suspension control arm assembly components can prematurely loosen, wear, crack, or break causing loss of steering control during operation. This issue has resulted in class action lawsuits and recalls. In 2020, China's State Administration for Market Regulation recalled approximately 40,000 Tesla Model S and Model X vehicles manufactured between September 2013 and October 2018 at Tesla's Fremont California facility due to this defect. The recall notice stated control arms may loosen or separate from the ball joint in extreme cases potentially breaking and affecting vehicle control, increasing crash risk with hidden safety hazards.
• Affected Components and Symptoms: Components prone to failure include front upper and lower control arms, front suspension aft-link, front suspension fore link, rear suspension upper link assembly, and rear suspension lower control arm assembly. The front and rear suspension control arm assemblies in Model S and Model X are reportedly identical, meaning the defect equally affects both models. Model 3 and Model Y also experience control arm issues, particularly upper control arms. Symptoms include clunking, knocking, or popping sounds especially when turning, braking, or going over bumps indicating loose suspension components or premature wear. In severe cases, the control arm can separate from the steering knuckle causing excessive negative camber where the affected wheel folds inwards. Some owners report complete wheel detachment in extreme failures creating immediate loss of control and severe crash risk.
• Tesla's Response and Controversy: Despite the China recall, Tesla took a different stance in the US, blaming issues on driver abuse. Tesla's corporate counsel reportedly told NHTSA that driver usage and expectation for damageability is uniquely severe in China market, asserting that curb impacts, potholes, and other types of abuse can damage suspension parts. Critics argue Tesla's willingness to blame drivers is concerning given the company has reportedly instructed service center technicians to conclude that snapped suspension arms are indicative of driver abuse rather than a defect. The class action lawsuit argues this blame-shifting is inappropriate given the widespread nature of complaints. The NHTSA investigated the alleged defect in 2020 but found no evidence of a safety defect requiring US recall, though many owners and consumer advocates disagree.
• Model Y TUV Report Findings: The 2026 TUV Report in Germany, which includes comprehensive EV evaluation for the first time, found the Model Y topped the ranking of vehicles with the most defects discovered during technical inspection. Previously the dubious honor fell to Model 3. According to the report, high defect rates are due to relatively weak suspension as the heavy battery weighs down on the axles. The German aftermarket parts specialist Meyle engineers found original Tesla control arms suffer from corrosion as water comes down the windshield onto the ball joint. Meyle developed reinforced replacement control arms with improved corrosion resistance and four-year warranty available in the UK market.
• Repair Costs and Prevention: Control arm replacement typically costs £200-£500 per corner depending on whether upper or lower arms are replaced, plus labor costs of £150-£300. Some owners report Tesla covering repairs under warranty while others are told the damage is driver-caused and not covered. When buying used Tesla vehicles, inspect suspension components carefully for wear, cracks, or corrosion. Request complete alignment check immediately after delivery of new vehicles. Inspect inner tire edges regularly as rapid uneven tire wear often indicates suspension problems. Consider upgraded aftermarket control arms with more durable ball joints and better corrosion resistance if issues recur. Have suspension components visually inspected at every tire rotation or service appointment. Owners in areas with harsh winters and road salt should be particularly vigilant about control arm corrosion.

Build Quality and Paint Issues (All Models):

• Panel Gaps and Misalignment: Panel gap inconsistencies are commonly reported on Tesla vehicles, particularly early production examples. These defects show up as inconsistent spacing or uneven panel heights affecting components like the hood, frunk, trunk, doors, and fenders. This signals inconsistent quality control during final vehicle assembly. While many view this as purely cosmetic, inconsistent panel gaps can cause wind noise, possible water intrusion, and long-term paint damage due to panels rubbing together. Panel gaps should be thoroughly inspected at delivery using a gap gauge or ruler to check alignment consistency. Tesla generally addresses panel gap issues within the short warranty window often 24 hours or 100 miles after delivery, so report defects immediately.
• Paint Quality Defects: Some Tesla owners report poor paint quality including chipping, peeling, fading, and thin paint application especially on early production models. Paint defects are more common on certain colors. UK inspection reports have cited Tesla Model 3 paint as not of good standard. Apply ceramic coatings or paint protection films to prevent chipping and protect against road debris. Schedule regular detailing for lasting durability. Wash vehicles regularly to prevent salt and debris buildup particularly in winter conditions that accelerate paint deterioration.

Rapid Tire Wear (Model 3, Model Y):

• Uneven Tire Wear Patterns: Rapid and uneven tire wear is commonly reported on Model 3 and Model Y, particularly affecting inner tire edges. This accelerated wear stems from suspension geometry, aggressive negative camber settings from factory, heavy vehicle weight from battery packs, and instant torque delivery causing tire scrubbing. Some speculate Model Y's heavier weight compared to Model 3 puts additional strain on suspension and tires. Symptoms include inner tire edge wearing much faster than outer edge, tires needing replacement after only 15,000-25,000 miles instead of typical 40,000-50,000 miles, and uneven tread depth across tire width.
• Solutions and Prevention: Request complete four-wheel alignment check immediately after taking delivery of new vehicle to ensure alignment is within specifications. Inspect inner tire edges regularly as rapid wear is often hidden from casual sight and not visible during normal walkaround inspection. Consider installation of aftermarket adjustable control arms to correct negative camber to street-friendly specification reducing inner edge wear. Strictly follow recommended tire rotation schedule usually every 10,000 km to balance wear across all four tires. Maintain exact recommended cold tire pressure specified on driver's side door pillar to ensure uniform contact patch with road surface. Adopt gentler approach to acceleration and aggressive cornering to minimize tire scrubbing effect from instant electric torque delivery.

Media Control Unit (MCU) and Screen Failures:

• Touchscreen and MCU Issues: The Media Control Unit is the central computer managing everything from infotainment to climate control in Tesla vehicles. Some owners experience MCU failures causing screen freezing, becoming unresponsive, going blank, slow system response, or complete failure. These issues were particularly common on early Model S and Model X with older MCU1 hardware. Tesla offered MCU upgrades from MCU1 to MCU2 or MCU3 for affected vehicles, sometimes covering costs under warranty and other times charging for the upgrade. Symptoms include touchscreen freezing during operation requiring reboot, system booting slowly taking several minutes to load after entering vehicle, blank or black screen with no display, loss of critical functions like rear camera, climate control, and navigation.
• Solutions: Try soft reset by holding down both scroll wheels on steering wheel simultaneously for 10 seconds to reboot the system which resolves temporary glitches. For persistent issues, Tesla service can perform MCU replacement or upgrade under warranty or for a fee depending on vehicle age and issue. Keep vehicle software updated through over-the-air updates which often include stability improvements and bug fixes. MCU replacement costs £800-£1,500 if outside warranty period.

Rearview Camera Failures (Multiple Recalls):

• Camera Circuit Board Shorting: Tesla has issued multiple recalls for rearview camera failures affecting 2024-2025 Model 3 and Model S, 2023-2025 Model X, and 2020-2025 Model Y vehicles. The computer circuit board may short resulting in loss of rearview camera image reducing driver's rear view and increasing crash risk. This violates Federal Motor Vehicle Safety Standard requirements for rear visibility. Tesla releases over-the-air software updates to address issues and also replaces affected computers experiencing circuit board failure or stress free of charge. Owners should install all software updates promptly when notified.

12V Battery Issues (All Models):

• 12V Battery Premature Failure: Despite having large high-voltage battery packs for propulsion, Tesla vehicles use a traditional 12V battery to power auxiliary systems, computers, and accessories. The 12V battery can fail prematurely causing various electrical malfunctions, inability to unlock or start vehicle, and warning messages on touchscreen. The DC-DC converter that charges the 12V battery from the main battery pack can also fail. 12V battery replacement costs £100-£200 and is straightforward maintenance. Tesla typically provides warning messages on touchscreen days or weeks before complete 12V battery failure allowing preventative replacement.

Air Suspension Problems (Model S, Model X):

• Air Suspension Component Failures: Model S and Model X equipped with adaptive air suspension can experience air compressor failures, leaking air struts, ride height sensor malfunctions, and uneven ride height. Symptoms include vehicle sagging especially after parking overnight, one corner sitting lower than others, warning lights on touchscreen indicating suspension system problems, harsh uncomfortable ride from failed air struts, and excessive compressor noise. Air suspension repairs are expensive with air strut replacement costing £500-£1,000 per corner, compressor replacement costing £800-£1,500, and complete system overhauls costing £2,000-£4,000. Regular inspection and addressing leaks early prevents more expensive failures.

Falcon Wing Door Issues (Model X):

• Complex Door Mechanism Problems: The Model X's distinctive Falcon Wing rear doors use complex mechanisms with multiple sensors, actuators, and articulated hinges. These can develop issues including doors failing to open or close properly, sensors incorrectly detecting obstacles, slow or jerky operation, and unusual noises during operation. Falcon Wing door repairs can be expensive due to complexity with actuator replacement costing £300-£800 per door and complete mechanism overhaul costing £1,000-£2,000+. Regular lubrication and keeping sensors clean helps prevent issues.

Software and Autopilot Glitches:

• Software-Related Issues: Tesla's advanced software and Autopilot system occasionally encounter glitches including phantom braking where the car brakes suddenly due to perceived hazards that don't exist, lane keeping assist oscillating or ping-ponging between lane lines, unexpected system reboots while driving, and connectivity problems with mobile app or navigation. Tesla regularly releases over-the-air updates to fix bugs and enhance features. Keep software updated, clear dirt and debris from sensors and cameras regularly, and report persistent issues to Tesla for resolution. Most software issues are resolved through updates rather than hardware replacement.

Tesla Reliability Assessment:

Dramatic Reliability Improvement: Tesla has made remarkable strides in reliability, rising from 27th out of 28 brands in 2022 Consumer Reports ranking to 9th out of 26 brands in 2025, marking a dramatic turnaround. Tesla also ranked 5th in maintenance and repair costs and 4th in owner satisfaction, demonstrating that while repairs can occur, they are becoming less frequent and owners remain highly satisfied. The improvement is attributed to fewer design changes compared to rivals allowing Tesla to refine manufacturing processes, improved build quality addressing early production issues, and standout electric drive system with fewer moving parts than conventional vehicles proving highly reliable.

Model-Specific Reliability: Model 3 achieves 84% reliability rating according to The Car Expert 2024 with core electric powertrain historically very strong. Model Y has average predicted reliability though 2026 TUV Report found it had highest defect rate during German technical inspections primarily due to suspension and brake issues. Model S and Model X have average reliability with main concerns being air suspension on equipped models and control arm issues on 2013-2018 examples. Cybertruck is the only Tesla model rated below-average in 2025 Consumer Reports due to being new with teething problems typical of first-year production vehicles. VehicleScore UK gives Tesla an excellent 879 out of 999 overall reliability rating based on real-world data.

Control Arm Issue Remains Primary Concern: Despite overall reliability improvements, suspension control arm failures remain Tesla's most serious issue affecting owner safety and satisfaction. The problem affects all major models though severity varies. When buying used Tesla vehicles, thorough suspension inspection is critical including checking for uneven tire wear patterns, unusual noises over bumps, and any signs of control arm damage or corrosion. Consider vehicles where control arms have already been replaced with upgraded aftermarket units as preventative measure.

Prevention and Maintenance Tips: To maximize Tesla reliability, follow these recommendations. Keep vehicle software updated by installing all over-the-air updates promptly which often include reliability improvements and bug fixes. Thoroughly inspect all panel gaps and paint quality at delivery and report any defects within 24 hours or 100 miles for warranty coverage. Have suspension components inspected at every tire rotation or service appointment checking for wear, cracks, or corrosion on control arms and bushings. Monitor tire wear patterns closely and address uneven wear immediately through alignment correction and rotation. Replace 12V battery proactively every 3-4 years before complete failure as preventative maintenance. For air suspension equipped models, address any leaks or sagging immediately before more expensive component failures occur. Clean all cameras and sensors regularly to prevent Autopilot and safety system glitches. When buying used Tesla vehicles, prioritize newer examples from 2020+ which benefit from improved manufacturing quality and design refinements. Verify all recalls and service campaigns have been completed. Request complete pre-purchase inspection focusing on suspension, tires, MCU functionality, and 12V battery health.

Overall Assessment: Tesla's reliability trajectory is positive with significant improvements year-over-year demonstrating the company's commitment to addressing quality issues. The electric drivetrain itself proves highly reliable with far fewer moving parts than conventional vehicles reducing mechanical failure points. Main concerns center on suspension components, build quality consistency, and software glitches rather than fundamental electric propulsion system issues. For buyers seeking cutting-edge electric technology with improving reliability, Tesla represents a compelling choice particularly newer models benefiting from manufacturing refinements. However, potential buyers should remain aware of suspension control arm issues and factor inspection costs and potential repairs into purchase decisions particularly for 2013-2018 Model S and Model X vehicles affected by control arm recalls in other markets.

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