Tesla is recalling more than 9,000 cars in the U.S. over a trim on the roof that could separate, increasing the risk of a crash, according to a regulatory filing on Wednesday, a rare physical recall for the automaker that has issued notices for millions of other vehicles this year.

The notice is a physical recall for Tesla, which usually fixes issues with its vehicles through … [+]

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The recall affects Model X SUVs manufactured in 2016, the National Highway Traffic Safety Administration said.

The SUVs are equipped with a cosmetic trim at the front of the roof just behind the windshield and another trim at the center of the roof, both of which could weaken over time, causing them to separate from the vehicle and increase the risk of injury or a crash, regulators said

Tesla said it launched an investigation into the defect in September 2020 after the automaker became aware of an unspecified “field event” involving a Model X car with the missing trim, which later determined the trims were attached with an insufficient amount of primer.

A voluntary recall of the cars was issued in November 2020, though Tesla said the fixes applied at the time were also insufficient.

As of Aug. 14, Tesla said it identified 40 warranty claims, six field reports and 125 service reports that may be related to the defect, adding it was not aware of any collisions, injuries or deaths caused by the defect.

Affected drivers will be notified by Oct. 14, Tesla said, and dealers will offer a free inspection and fix.

2.5 million. That’s the number of cars Tesla recalled through the first six months of the year, behind only Ford (3.6 million) for the most recalled in this period, according to NHTSA data.

Tesla has issued several recalls this year, though most notices involve an over-the-air software update to fix the defect. The automaker recalled over 1.8 million cars last month, including some Model 3, Model S and Model X vehicles manufactured between 2021 and 2024, among others. Those vehicles were equipped with an unlatched hood that could fully open, obstructing the driver’s view and increasing the risk of a crash, regulators said. Another 2 million vehicles were recalled in February for small font sizes on warning panels that regulators said could increase the risk of a crash. More than 125,000 cars were recalled in May because of a software issue preventing the seat belt warning system from activating.