Tesla Cybertruck Owner Says, “I Had My Tailgate Replaced Due To Warping and the New One Came In Looking Even Worse”

This Tesla Cybertruck owner is hitting a bumpy road in his first experiences. This account of the Tesla Cybertruck tailgate is far more metal than owners expected.

Patrick Bishop shares on the Cybertruck Owners Only Facebook page. He says, 

"I had my tailgate replaced due to some warping, and they allowed me to keep the old one. Planning to make an armory desk for cleaning my stuff. Any other ideas?"

Another Cybertruck owner, Wayne Unkefer, says, "I had mine replaced, and the tailgate they installed is worse than my first one! Now they told me that engineering has halted tailgate replacement until they resolve the issues. Can you share a screenshot of the invoice document so I can take it to the service center?"

Patrick says, "I don't have it, unfortunately. I just happened to see the restocking fee on their screen. I'm really glad they called and confessed that the new one came in looking worse. I went and looked in person, and it looked terrible."

"I didn't see the price, but I did see the restocking fee was $423, which is 10% so it's approximately a $4,000 part plus labor, probably around $5-6k."

Why Tesla Halted Cybertruck Body Panel Replacements

This week, we're looking into the issue of warped Cybertruck tailgates, and a quick scan of social media shows that this isn't an isolated incident. 

The reports from Patrick Bishop and Wayne Unkefer on the Cybertruck Owners Only Facebook page provide a revealing view into the current state of Tesla service, quality control (QC), and the high cost of replacement exoskeleton parts.

The Problem: A Halt in Service and a Worse Replacement

Wayne Unkefer's experience is precisely why I pay close attention to owner reports. Wayne had his tailgate replaced once, only to find the new unit was "worse than my first one." The follow-up is crucial: the Tesla service center informed him that engineering has halted Cybertruck tailgate replacements until the underlying issues are resolved.

This halt is an admission that the replacement parts being shipped are failing to meet factory standards—or, worse, failing to fit the unique tolerances of the stainless steel unibody. 

When Tesla halts any service or repair, it indicates that the manufacturing process has encountered a design flaw that needs fixing at the assembly level, not just the service level.

The Deeper Issue

The estimated expense of $4,000 for the part alone drives the total repair cost into the $5-6k range, according to the restocking fee calculation Patrick was privy to. This figure, validated by a disclosed 10% restocking fee of $423, is astronomical for a tailgate, even for a high-end pickup.

This could be a preview of the future of Tesla service repair costs for Cybertruck parts. The stainless steel exoskeleton, while incredibly tough, is non-conventional. It requires specialized tools, unique processes, and highly trained personnel, justifying the premium price.

What Should Cybertruck Owners Do Now?

Because repair costs are transferred directly to the owner, having proper documentation for warranty tracking is critical from day one.

So, why is Tesla Cybertruck production facing quality control issues in the first place? A report from Metal By the Foot says the primary suspect is the unique properties of the cold-rolled stainless steel. Unlike traditional sheet metal that can be easily massaged and shaped, stainless steel is notoriously unforgiving.

It expands and contracts significantly under thermal stress, and the sharp, zero-radius folds used in the Cybertruck's design can exacerbate tension points if the initial stamping or fitment tolerances are off by even a millimeter; that discrepancy compounds across the entire panel, leading to the visual and functional warping we are seeing reported.

What Next For Cybertruck Owners?

If you are waiting for a replacement, as in Wayne's case, owners must be patient, no matter how frustrating that is. The service center's honesty about the replacement being worse is a good sign. However, owners should document everything with photos and timestamps. Use Wayne's report about the replacement halt to press the service center for an official internal communication number. 

The immediate takeaway for every owner seeking a repair is to wait for the engineering solution before proceeding. Do not accept a known-faulty replacement part.

Conclusion

The Cybertruck is an industry disruptor, but this level of innovation brings growing pains. The reported engineering halt on tailgate replacements and the $4,000 cost for the part underscore the high-stakes environment for this unique vehicle. Tesla's immediate challenge is to achieve consistent panel quality and resolve the fitment problems inherent to its complex stainless steel construction.

The good news is that Tesla is aware of the issue and is addressing it at an engineering level, which is far better than simply pushing out substandard replacement parts.

Key Question for Cybertruck Owners

Considering the confirmed $4,000 price tag for a single replacement tailgate, and knowing these repairs could push repairs outside the warranty window, do these high parts costs change your long-term cost-of-ownership calculation for the Tesla Cybertruck? Let me know your thoughts in the red Add New Comment link below.

Check out my Tesla Cybertruck story: Tesla Cybertruck Owner Says, “It’s a Futuristic Chrome-Plated Dumpster Designed On an Apple II By a Stoned Elon Musk, But Requires Less Maintenance Than a Goldfish”

I'm Denis Flierl, a Senior Torque News Reporter since 2012, bringing over 30 years of automotive expertise to every story. My career began with a consulting role for every major car brand, followed by years as a freelance journalist test-driving new vehicles—equipping me with a wealth of insider knowledge. I specialize in delivering the latest auto news, sharing compelling owner stories, and providing expert, up-to-date analysis to keep you fully informed.

Follow me on X @DenisFlierl, @WorldsCoolestRides, Facebook, and Instagram

Photo credit: Denis Flierl via Patrick Bishop