NHTSA Complaint #11498194 — 2014 TESLA MODEL S

Rear lower control arm broke, causing extreme twitch and near loss of vehicle control about 1/4 mile before getting on highway. There was a loud ping in a parking garage the day before while turning, but nothing seemed to be wrong with the car at that time and I assumed there must have been a water bottle cap or something that went under the tire (can't see ground well in a tight parking garage, which had some litter here and there). Drove about 30 miles home without incident. I suspect that the control arm was only fractured at that point, but retained enough metal to hold the wheel in place (terrifying to think we were driving at highway speeds like that). The following morning, reversed out of garage and was approaching highway at neighborhood speeds when car veered very suddenly. Immediately returned to garage and changed to my other car. Found the control arm completely separated when inspecting it that evening. Part was revised and cars built just prior to mine (same part number) were covered by a TSB. Tesla refused to offer any TSB coverage and are the sole supplier of replacement parts ($350/each). This kind of part does wear out but should not catastrophically fail-- appears to be poor quality part, cast, or metallurgy. It was nearly a huge accident twice, and both times would have been at highway speeds. As unnerving as the sudden skew was, it was the best warning/outcome I could have since Tesla did not recall this widely reported failure. I don't understand how production dates take precedence over part numbers when TSB/recalls are issued -- it makes no sense.