It appears that Tesla’s rear casting and structure improvements for the Model Y have been designed to improve the safety of passengers who will occupy the vehicle’s future third row of seats.
As Sandy Munro continues to dive into the company’s new all-electric crossover, several clues hint toward the vehicle’s improved rear safety design. Munro mentions multiple design improvements that range from thicker longitudinal bars to prevent crunching in the even of an accident, to new bolt shapes that decrease weight and improve durability.
Munro first looks at the castings on the side rails of the Model Y. The attachment points on each side of the car indicate they are one piece and are not welded on. “They’re plenty strong, and you can see they’re just cast in place,” he said. Also, the under-seat points are 3 to 3.5mm thick. Munro suggests Tesla moved added density to other areas that may be more susceptible to being compromised in an accident. “There is a lot of good stuff here. I like that.”
According to Munro, Model Y has improved fixture points on the rear longitudinals that run from the front to the back of the car. While the two bolts on the front of the longitudinals are standard, the top bolt on the rear end is scooped out. “These are common on Japanese cars. See how it’s dished out? The Japanese use this for weight reduction, but it is also good for a shear bolt. So my guess is this may be something to do with crashworthiness,” Munro said.
Shear bolts are commonly used to protect equipment from sudden impact or excessive load. They are often referred to as “anti-theft bolts” and popular among assemblies that may be subjected to occurrences of excessive force. However, they are ideal for safety and an accident would maintain the structural integrity of the rear portion of the car, keeping those seated in the back safe from injury during a violent collision.
Speculation from the Detroit veteran suggests the Model Y’s third row of seats will be rear-facing, especially as the design of the mounting brackets only leads Munro to believe that the sixth and seventh passengers will be looking out of the vehicle’s rear windshield.
“We can’t see anything that says that we’re going to be putting front-facing seats. But, we sure can see where it could be a potential there for rear-facing seats,” Munro said.
A video Munro posted on April 4 to the company YouTube channel examined the Model Y’s potential for rear-facing third-row seats. Munro hopped into the trunk of the crossover and was impressed by the size and spaciousness, and mentioned that it was “semi-comfortable” and may be best for children based on its storage design.
Based on what is known about Tesla’s previous and upcoming third-row seating options, the design would likely be rear-facing. Jump seats in the Model S were popular among the sedan’s owners before the release of the Model X. Additionally, the upcoming release of the Plaid Mode Model S will include rear-facing jump seats that will support larger passengers instead of just children.
The Model Y was always aimed toward being the safest midsize SUV on the road. With the inclusion of an optional third row of seats, the Model Y’s rear collision safety had to be revamped and rejuvenated. The addition of shear bolts for durability and increased thickness in some areas for added strength was likely added to improve the safety of third-row passengers in an accident.
Watch Munro’s video of the improved rear castings and safety design of the Model Y below.
A Tesla Semi caught fire in Hayward, California, which caused both directions of traffic to shut down for hours before being completely reopened early on Wednesday, the California Highway Patrol said.
The fire occurred just after 5:30 local time in Hayward on Tuesday, as the Semi caught fire in the southbound lanes of I-880 before CHP officials made the decision to shut down both lanes of traffic due to potential risks from hazardous chemical smoke.
There were no injuries reported.
🚨 A Tesla Semi reportedly caught fire, with California Highway Patrol confirming. The Semi was on I-880 SB
An estimated 5,000 to 7,000 semi-truck and large commercial vehicle fires occur on U.S. roadways every year
— TESLARATI (@Teslarati) October 28, 2026
The cause of the fire is currently unknown, as neither Tesla nor the CHP have not determined a cause.
However, some images taken before the Semi was completely destroyed by the fire seem to indicate this might have been an older unit, as it appears to be one of the designs that Tesla shipped as part of its pilot program, before revising it and starting mass production just a month ago.
@Tslachan From on of the videos looks like it’s an old Semi (not the refresh version that recently started production) https://t.co/KzwmR2kXow
— Area Under The Curve 🎗️ (@AreaUnderCurve) October 28, 2026
At the time of publication, CHP had not returned our request for a comment for additional details, including the Semi involved and any potential collaboration on an investigation between the CHP and Tesla. We will update this story when we hear back from them.
The southbound lanes were reopened at 3:30 a.m. on Wednesday, with the northbound lanes opening last night a few hours after the fire began. The CHP did state that the lithium batteries were “incredibly difficult to extinguish,” according to NBC Bay Area.
The truck’s driver said that the Semi caught fire, but he did not have an explanation.
An estimated 5,000 to 7,000 semi-truck and large commercial vehicle fires occur on U.S. roadways every year.
Tesla’s launch of the “Emergency Drive Away” function a few months back offered owners a safe option to evacuate an area if they were in reasonable danger. The function finally got its first use in the real world, but it appears it was by mistake.
A video shared by u/Joshalander in the r/TeslaLounge subreddit recorded the instance from his vehicle and said the incident took place in Austin this past weekend during the city’s F1 Race.
“Was charging around 6 AM this past Sunday in Austin before heading to the F1 race and heard a pop. Looked over and saw the new emergency drive-away feature in action. Genuinely felt bad for the dude when he got out and realized what happened, since he looked exhausted and only seemed to half-read the prompts.”
🚨 Here’s the first look at Tesla’s Emergency Drive Away function in action:
Apparently this driver accidentally enabled it and drove forward; you can see the Supercharger pull with the car.
Tesla said previously this would cost up to $25k if not used properly. https://t.co/B4qQRrsO6B
— TESLARATI (@Teslarati) October 28, 2026
Emergency Drive Away unlatches the Supercharger connector from the vehicle, but still causes damage to both the car and the Supercharger. Tesla has said that it will cost up to $25,000 in repairs to have everything fixed back to normal.
Additionally, the company said that if it were not used in an emergency situation, the driver of the vehicle who activated the Emergency Drive Away feature would be responsible for all repair costs.
Tesla constitutes the following situations as reasonable justifications for activating the feature:
- You face an immediate threat to your life or personal safety.
- You must leave the area immediately.
- Exiting the vehicle is unsafe.
- Unplugging the charge connector would unreasonably delay your departure or expose you to a risk to your personal safety.
After using the feature, Tesla requires the driver to schedule Service so the car can be inspected.
News
Tesla’s Cybercab battery design could make robotaxis even cheaper
Tesla built the Cybercab’s battery pack with spare room for a future switch to LFP.
Tesla built the Cybercab’s battery pack with empty space inside it on purpose, and the reason points to a cheaper robotaxi down the road.
Robert Sumpf, Tesla’s director of mechanical design engineering for battery modules and packs, said the extra room beside and beneath the Cybercab’s modules was left there so the company can move to lithium iron phosphate cells later. “So, we protected this pack to go to an even lower energy dense chemistry as we scale and need to bring LFP into the platform,” Sumpf said in a Cybercab deep dive with Munro Live.
The Cybercab runs on Tesla’s own 4680 cells with a nickel chemistry today. LFP cells store less energy for their size, so a straight swap would cut range. The reserved space lets Tesla add more LFP cells to make up the difference. In return, Tesla would get cells that cost less, run cooler and survive more charge cycles. LFP became the most used EV battery chemistry in the world last year.
Not all of that room was planned for a chemistry change. Lars Moravy, Tesla’s Vice President of Vehicle Engineering, said part of it exists because “we didn’t need as many batteries as we thought we did.” Tesla told Sandy Munro in early 2025 that it was targeting a Cybercab pack under 50 kWh with close to 300 miles of range.
The pack also breaks from the structural design Tesla used in some Model Y and Cybertruck builds. Instead of potting hundreds of cells into one block, the Cybercab uses four separate, individually sealed modules, so a bad module can be replaced without scrapping the whole pack. Sumpf was blunt about the older approach, giving the Model Y structural battery “a grade D” because it was hard to build and nearly impossible to repair. He estimated a fully structural pack gains about 10% more cell volume, but said “the issue is the service cost.”
That cost matters more for a car that rarely sits parked. Cybercab chief engineer Eric Earley said replacing an entire pack “before half a million miles is a killer on cost,” which is why remanufacturing and serviceability were built into the design from the start.
The same Munro Live tour produced Moravy’s admission that the Cybercab line at Giga Texas is now outpacing Robotaxi deployments, along with a look at the robotaxi’s unorthodox paint process. Tesla is aiming to deliver the first Cybercabs to outside customers by the end of 2026, though Elon Musk has said the vast majority will stay owned by Tesla and run as a transport service.
Sumpf did not give a date for an LFP version, name a cell supplier or say how a chemistry change would affect range. For now, the 4680 cars keep piling up: Texas DMV records from Tuesday list 544 Cybercabs authorized for Tesla’s Robotaxi fleet, more than the 507 Model Ys on the same roster for the first time.
Tesla Semi catches fire in California: what we know
Tesla’s ‘Emergency Drive Away’ function gets its first use in the real world
