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Main Battery Module Failure

Discussion in 'Model S: Battery & Charging' started by TonyWright, Jan 22, 2016.

  1. TonyWright

    TonyWright New Member

    Joined:
    Nov 13, 2011
    Messages:
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    Location:
    West Newbury, Massachusetts USA
    Has anyone else had a Tesla battery module failure? Are there statistics posted somewhere?

    My freshly charged 2014 60KwHr Tesla (22,000 miles) exhibited a completely dark screen one morning last week when I went into my Garage to drive to work. Deep sleep reboot was to no avail. Tesla sent out a Tow truck. I did not know this, but behind the removable front grille there is an emergency 12V battery post from which the computers and displays can be booted from a portable lead acid battery. There was good news and bad news. The car could be placed in tow haul mode through the lit displays, BUT there was insufficient power for the car to be driven. So we pushed the car out of the garage by hand and they took it away. 2 Days later they called back and said they found one of the high voltage lithium battery modules contained at least one or more failed cells, a fault detected by the monitoring electronics, so the car would not allow operation. Tesla will give me a loaner module, return the car, and send my module back to the factory to be rebuilt.

    This raises interesting questions. Although the cells are said to be exceedingly reliable, if the car has over 4000 of them, then the odds of a failure increase. Apparently there is no mechanism to automatically lock out a bad battery cell, and continue driving, unless perhaps a fuse is blown, so it will be interesting to see how many modules Tesla will have to be rebuild within the 8 year warranty period!

    FYI, I had the previous week driven 150 miles and back to Loon Mountain NH to Ski. I used the supercharger in Hooksett twice, and the 30 amp charger at Loon. I would not have wished this failure to happen in ski country, 180 miles from the nearest Tesla service center.
     
  2. Rocky_H

    Rocky_H Member

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    Location:
    Boise, ID
    I’ve been following the forum at the main TeslaMotors site for about 2.5 to 3 years, including the private owners’ threads, and I do recall seeing one thread about a failed module in the main battery. So yes, it has happened before, but it seems to be very rare. I tried to find it, but since search tools can’t see inside private threads, I think that’s why it’s not coming up.
     
  3. TonyWright

    TonyWright New Member

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    Nov 13, 2011
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    Location:
    West Newbury, Massachusetts USA
    To follow up my post: The key High Voltage power pack problem turned out to be: "Power switch update bulletin performed and replaced HV pack fuse and hardware as
    required." This was due to "power switch impedance above normal levels." So the very good news was that actual battery cells did not fail. This greatly increases my confidence in Tesla technology! My model was a 2013 model and there have been some hardware updates TonyWright
     
  4. Troy

    Troy Member

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    Yes, this survey has a stats page. Out of 222 owners, 15 said they had a battery replacement. That's 6.8%. A year ago it was about 9% which means newer cars have less battery pack failure.
     
  5. apacheguy

    apacheguy Sig 255, VIN 320

    Joined:
    Oct 21, 2012
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    3,728
    Location:
    So Cal
    Ok, great. So you had contactor failure. Not a failed module. Mods, can we update the thread title?

    Only one forum user (ken830) had a module failure. They are extremely rare.
     
  6. Lex

    Lex Member

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    Apr 23, 2015
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    Location:
    Toronto, Canada
    #6 Lex, Jan 28, 2016
    Last edited: Jan 28, 2016
    Good to hear, I guess. My pack ("module" ??) melted down today :wave oops did I just mess up the modding of this :confused

    Regen was halted, power was drastically reduced (least amount I'd ever experienced, I could usually not get it to the speed limit and had to use hazards a lot). It threatened that it may not come back on so I used camper mode to keep it on at a meeting and then we crawled back to the shop.

    They told me a new pack is on the way from the factory.

    Like with other issues, thankfully they seem to be dramatically improving over time. And they know it's an evolving technology, thus the warranty.

    PS coming from a Chrysler family, I love all kinds of "limp modes" saved me a lot of hassle today. Thank you Tesla.
     
  7. GoBlue88

    GoBlue88 Member

    Joined:
    Apr 1, 2014
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    638
    Location:
    San Diego area
    My battery heating unit failed last week while I was at the Barstow Supercharger, rendering the car undrivable 115 miles away from the Costa Mesa service center. Tesla provided me a rental car and had the MS transported to Costa Mesa for repairs, and I was continuing my trip to Vegas in a very comfortable GMC Yukon within 45 minutes of calling roadside assistance. Weekend not ruined, and I picked up my car on the way home from Vegas a few days later. So yeah, while it is an awful feeling to have a dead car far from a service center, Tesla can deal with it in a very efficient and customer friendly manner.

    Thread on it here: Battery coolant heater failure
     
  8. mikeg561

    mikeg561 Member

    Joined:
    May 18, 2015
    Messages:
    112
    Location:
    huntington beach, ca
    I had a failure and had to have the main battery pack swapped out after 2 or 3 days of taking delivery of my new 2015 85d.

    Tesla gave me an 85p loaner. :)

    Mike
     
  9. Alysashley79

    Alysashley79 Member

    Joined:
    Oct 4, 2013
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    646
    Location:
    Seattle, WA
    I had a failure on my pack (d pack) not sure yet what the exact failure was only know that I have a loaner pack (the wonderfully dreaded A pack) on my car right now and for the next 3-4 months while my pack is sent to the factory for testing and hopefully to be fixed.
    what I was told was that I had a leak into my pack. I have no idea how it happened. I have around 67k on my car and pack.
     

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