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I am now on my 4th drive unit. The original drive unit started milling around 20,000 miles and was replaced at 24,000 miles. The second drive unit failed on Tesla's test drive and was therefore replaced immediately. I had high hopes the third drive unit (remanufactured) would be a keeper. The milling and shim issues were well known at that time. Unfortunately that was not the case. The Third drive unit started milling again after around 20,000 miles. This was noted during my car's annual. It was scheduled to be replaced at a later time due to a high demand for replacement non-performance drive units. So that got done today. None of the drive units ever failed outright (except of coarse the DOA one that Tesla had to deal with). They were just noisy. How noisy? Not very bad. You could hear them much more when the windows were open and the sound reflecting back into the car. But I suspect they would slowly get worse and get more annoying over time. If I had to guess, I could have driven it another 25,000 miles this way without too much of an issue.
That said, it is still my biggest long term concern with this vehicle. Changing drive units annually is not going to be good for Tesla in the long term. The 4th drive unit is also a remanufactured unit (was hoping for a brand new one). But it should still have the latest fixes, if there are any. Time will tell. I will report back on this subject in about a year or so (roughly 25,000 miles) and let you all know how it is holding up.
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