A limited number of Polestar 3 electric SUVs are being recalled before even reaching customer hands, due to a significant safety issue stemming from a previous production correction. This group consists of just 19 vehicles, but they had already undergone a rework during manufacturing. Unfortunately, it was during this corrective process that a new problem was introduced. The issue revolves around the panoramic glass roof, which, under certain conditions, could potentially detach while the vehicle is in motion—a hazard that could pose serious risks to both occupants and other road users.
The root of the problem traces back to a paint correction procedure performed during production. While repainting, technicians used masking tape to protect various surfaces. However, Polestar suspects that in some cases, this masking tape was not properly removed afterward. If remnants of tape were left behind near the joint between the panoramic roof and the car’s frame, it could compromise the adhesion between the glass and the vehicle's body. The irony, of course, is that using tape to protect the vehicle may have actually caused two key components not to stick together properly.
Polestar has outlined a few ways for concerned owners to determine whether their vehicle may be affected. While the most reliable method is checking the VIN (Vehicle Identification Number) through either the National Highway Traffic Safety Administration (NHTSA) database or a local dealership, the automaker also points out some physical warning signs. These include unexpected water leaks inside the cabin, an increase in interior noise levels, and potential malfunctions in certain electronic systems. Such symptoms could indicate that the glass roof is not fully secured.
Perhaps the most alarming possibility Polestar mentions is that, under rare and extreme circumstances—such as high-speed driving on rough terrain or sudden acceleration or braking—the panoramic roof could detach entirely from the car. However, the automaker emphasizes that this outcome is highly unlikely and would only occur under very specific and intense conditions. Despite the seriousness of the defect, it affects only a very small number of vehicles, and the risk of actual roof separation is minimal.
For owners of the affected Polestar 3 models, the company will correct the issue by removing any remaining masking tape and replacing the entire panoramic roof. Vehicles manufactured after December 3, 2024, are not impacted, as the problem was resolved in production lines after that date. Notification letters to inform affected customers are scheduled to be mailed by August 18.