My list is similar to the OP, save for the battery pack replacement, which is bigger than my problems. My impression from others at TMC is that I have been more unlucky than most!
[May 2014 build S-60, purchased CPO with fewer than 7000 miles on it. Currently at 94,800 miles.]
Warranty:
•Door handle: replaced by SLC UT service center because they didn't have parts for a repair. (17,197 miles)
•Failed UMC on road trip: replaced by Tigard OR service center. (28,024 miles)
•Noisy drive unit: replaced by Littleton CO service center (this was an expected repair when I purchased my used car; I got a Q version refurb DU and it has been completely quiet for more miles than the original). (40,260 miles)
•MCU failure: Mobile service didn't have a replacement in stock so they transported my car 300 miles across the mountains to Littleton and dropped off a rental car. New MCU1 with LTE installed. (44,314 miles)
•Dust shield and right front knuckle joint: replaced by Littleton CO service center. (44,314 miles)
•12V battery failure: replaced by mobile service. (45,712 miles)
•Steering bolt recall: replaced by Littleton service center. (55,020 miles)
•Lug nuts on one wheel were loose after an earlier service: took my car all the way to Littleton to make sure no damage had occurred after several thousand miles of driving before I discovered the problem, including freeway driving at 80 mph. No issues found. (57,488 miles)
•Passenger side airbag recall: replaced by mobile service. (91,863 miles)
Out of warranty:
•Door handle (same one as before): repaired by mobile service. (66,824 miles)
•Car dead and unresponsive in garage, charge cable could not be removed: had car transported 300 miles across mountains to Littleton service center. Transport quote from Tesla roadside was $1400 from a local company; they suggested that I contact my insurance company. I did that and State Farm arranged for the flatbed transport at no cost to me because Littleton was the nearest place the car could be serviced. After a wait of a few days during the end of quarter sales push, Littleton got on it the first day of the next quarter and told me that it took them nine hours to find the problem: a corroded wire to my charge port. They replaced the charge port because of cosmetic damage while they were working on it. Service comped me on all but one hour of repair time
and they picked up the cost of my rental car to get to Littleton to pick up my car (my S-60 is my only car and I live alone — had to get a neighbor to take me thirty-five miles to pick up the rental). Needless to say, despite the inconvenience and worry I was
very pleased with how I was treated by Littleton service. (68,468 miles)
•Door handle: repaired by mobile service. (91,863 miles)
My car has been out of warranty awhile, 38,000 miles and almost two years, but I am happy with it and hope to keep it for many years more. My battery is down about 14% in capacity, to about 179 RM, and that makes some road trip legs difficult. My inclination, however, is to have another battery installed at my expense if the range gets to be too low to be practical. As the Supercharger network increases in density, trip leg length is becoming less of a problem in most places. So far so good.
I do wish I could get the eMMC chip replaced but the idea of taking my dash apart and removing my MCU is
way beyond my comfort level, especially after watching the air bag replacement. Still mulling it over, however. Tempted to make a road trip to Orange County and just drop my car off with
@TonyT and rent a car until it can be fixed. It would be worth the peace-of-mind!