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Max Range of 13 P85 Dropped 10% Overnight, Voltage Fault Detected

A couple of weeks ago my Tesla lost 10% of its max range overnight. I scheduled a mobile tech and a few days before the appointment Tesla called me and said I needed to bring it to my local SC and scheduled an appointment. They said they saw some errors with their mobile diagnostics. I took my car in to the SC on the scheduled date and they said it would be done following day. They ended up pushing pickup off twice for further diagnostics. When I went to pick up the Tesla they said nothing was wrong and to take my car. I further inquired with my service advisor who admitted they detected a voltage fault in the battery but it’s all normal. I asked to speak to the technician and he said no problem. I waited around over 30 minutes and the technician didn’t come up. He went back and the technician said he has nothing further to tell me and wouldn’t come up. The service advisor said I have one of the “rare cars” who’s battery is showing degradation. He also said to drive it 4-6 weeks and it will even out. Before bringing it in I tried to recalibrate the battery by driving it under 10% leaving it overnight and charging to 100% twice. Both times it would not charge to 100% and stopped at 96% and 97% and couldn’t be forced to charge anymore. My issue is my p85 2013 battery warranty is up in 4 weeks. I also believe if the battery degraded it would have happened over time and not lose 10% of max range overnight at the same time a voltage fault was found. To me it sounds like the voltage fault damaged the battery. What do you guys think and suggest? I tried again (third time) to drive it below 10% and charge to 100%. It would only charge to 95%. If battery won’t charge to 100% (not indicated mileage) they should replace this obviously damage battery under warranty right?
 
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Akikiki

A'-Lo-HA ! y'all
Nov 26, 2012
6,536
4,891
Kaneohe, HI
I can't help you with your situation. But. Some of us that had '13's - that had problems. "We" paid attention to others reporting problems. It was common knowledge there were a variety of A & B Battery issues back then. In those days, Tesla was putting loaned batteries in early cars. Most with battery issues had the battery returned to factory, rebuilt/refurbished and returned to be re-installed in original car. I was told by SC that it was company's intent to track those batteries by keeping them in original car.

In Oct 2016, my Sep 2013 built P85 suddenly had a battery fault. the range dropped overnight from 243 to 57 miles. Would not charge. SC sent a flatbed. That same day they reported the battery fallen "out of balance". They ordered and installed a rebuilt battery. I was told to expect to get a call to bring my P85 back in for the original battery to be put back in. Mine never came back to my car. I guess they had learned enough about what was going on with some of those early batteries that there saved the trouble and expense of returning same battery and moved on to other issues.

You - close to battery expiration, I would use the app, make another appointment, so there's a record. I would detail my worse fears about what's happening to the battery, getting in down in b&w. Print out all the details you can to hard and ecopy. Then go to the SC for a talk. You want them to acknowledge the work request with your concerns. Get anything in writing or comment on your work request, so your copy has a record. Now, up to you what you get them to put on your copy. Something to do with complains before warranty expires, I guess. Good luck.
 
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Gixx1300R

Member
Dec 30, 2017
739
1,263
orlando
A couple of weeks ago my Tesla lost 10% of its max range overnight. I scheduled a mobile tech and a few days before the appointment Tesla called me and said I needed to bring it to my local SC and scheduled an appointment. They said they saw some errors with their mobile diagnostics. I took my car in to the SC on the scheduled date and they said it would be done following day. They ended up pushing pickup off twice for further diagnostics. When I went to pick up the Tesla they said nothing was wrong and to take my car. I further inquired with my service advisor who admitted they detected a voltage fault in the battery but it’s all normal. I asked to speak to the technician and he said no problem. I waited around over 30 minutes and the technician didn’t come up. He went back and the technician said he has nothing further to tell me and wouldn’t come up. The service advisor said I have one of the “rare cars” who’s battery is showing degradation. He also said to drive it 4-6 weeks and it will even out. Before bringing it in I tried to recalibrate the battery by driving it under 10% leaving it overnight and charging to 100% twice. Both times it would not charge to 100% and stopped at 96% and 97% and couldn’t be forced to charge anymore. My issue is my p85 2013 battery warranty is up in 4 weeks. I also believe if the battery degraded it would have happened over time and not lose 10% of max range overnight at the same time a voltage fault was found. To me it sounds like the voltage fault damaged the battery. What do you guys think and suggest? I tried again (third time) to drive it below 10% and charge to 100%. It would only charge to 95%. If battery won’t charge to 100% (not indicated mileage) they should replace this obviously damage battery under warranty right?
Tesla is going to use delay tactics until your warrant is over, That is why they told you to drive it for 4-6 weeks and it will even out. Have them put everything in writing, nothing verbal. Keep all paper and escalate a claim quickly. If I were you I would hire a lawyer as soon as possible.
 
This is the response from Tesla I received today. It seems they are doing to my battery EXACTLY what they just settled the 1.5m lawsuit for battery gate over. And in addition my max rated miles didn’t go up when they gave it back to me so if it reduces further over the next 4-6 weeks (putting me out of warranty) it will be even worse. Do you think they’ve crippled my pack with a batterygate esq software/firmware update? Any suggestions?

from Tesla

We've created a case and escalated it to local field technical specialists, they've reviewed your concern and vehicle vitals and determined this to be due to firmware. They state your HV battery experienced inaccurate voltage measurements which led to artificial lower range available at full charge. They have fixed the issue with a software update; this may cause the range at full charge to increase at first. However, the HV battery will need a few weeks to fully balance and calibrate this new repaired measurement. This may translate to some reduction of range at full charge over 4 to 6 weeks after the software fix is implemented. The system can reduce max charge level of the cells down by about 7% compared to initial charge level. From there, the cells will be operating in an optimal range maximizing long-term retention, performance and range at full charge stabilizes. I hope this answers your questions. There is nothing more that can be done at the Service Center, so with your permission, I will cancel your appointment.

Tim Sutliff
 
No, I would think it means that there was something wrong with the battery and they repaired it, under warranty.
They said the voltage error lead to artificial lower range available at max charge and that the new range at full charge would increase at first before lowering once calibrated. The problem is the range didn’t increase at all at first. It’s the exact same as when I brought it in. Reducing the charge level of the cells by 7% artificially isn’t what I purchased when I bought this car thinking it was warrantied. Natural degradation is to be expected. Not a capping off the battery by software due to a problem with the bc battery.
 
In addition my battery still won’t charge to 100%. I have attempted to drive it below 10% and back up to 100% three times. Not once was charging complete at 100%. It stops at 94-96% and can’t be forced to charge anymore.
If the charge stops at 94-96%, my guess would be there is an imbalance between the bricks in the battery.
One or more bricks have a higher voltage than the others causing the charge to stop as soon as the first bricks hits the max voltage.
Since all the other bricks have a lower charge than 100%, this will probably explain the loss of range.
It would seem the imbalance can't be corrected by the BMS, so my guess is it will get larger over time and eventually the BMS will start displaying errors, the battery is faulty and needs to be replaced.
It sounds like Tesla knows this and just wants to delay replacing the battery, hoping the BMS wont display faults until after your warranty expires.
 

Gixx1300R

Member
Dec 30, 2017
739
1,263
orlando
We've created a case and escalated it to local field technical specialists, they've reviewed your concern and vehicle vitals and determined this to be due to firmware. They state your HV battery experienced inaccurate voltage measurements which led to artificial lower range available at full charge. They have fixed the issue with a software update; this may cause the range at full charge to increase at first. However, the HV battery will need a few weeks to fully balance and calibrate this new repaired measurement. This may translate to some reduction of range at full charge over 4 to 6 weeks after the software fix is implemented. The system can reduce max charge level of the cells down by about 7% compared to initial charge level. From there, the cells will be operating in an optimal range maximizing long-term retention, performance and range at full charge stabilizes. I hope this answers your questions. There is nothing more that can be done at the Service Center, so with your permission, I will cancel your appointment.

Tim Sutliff
Tesla is stalling until your warranty is up
 
Should I continue to drive it below 10% and try and charge up to 100% while it’s under warranty? Will this help the true problem show itself?
I think the imbalance is probably too great to be fixed automagically by the BMS.
You could insist Tesla rebalances the battery for you, where they will run it through a series of slow charge-discharge cycles.
When the battery is properly balanced, it should charge to 100% again, but you might not get all your range back.
 

Akikiki

A'-Lo-HA ! y'all
Nov 26, 2012
6,536
4,891
Kaneohe, HI
I've never heard before of a healthy batter not charging to 100%. But please be careful. Just in case you didn't already know, never charge to 100% unless you are very soon/almost immediately start driving to reduce that 100%. We've been told, that charging to 100% then not starting a discharge i.e., driving is almost the worst thing you can do to a Tesla regarding charging. And be advised, Re-Gen will not work, because there's no place for excess juice to go until you have used some of that 100%.
 

FoxSTL2HOU

Member
Nov 12, 2018
526
310
HOU
On the charge screen, is the charge level/percentage matching the charging tickmarks, so there is a gap when the car stops short of your desired level, or do the tickmarks reflect a lower charge level?

I have noticed the latter the past couple of months on my vehicle. Example: I set my desired charge to 80% aka the second tickmark from the right. Charging finishes at 77%, but there is no gap between the charge level and the 80% tickmark.
 
On the charge screen, is the charge level/percentage matching the charging tickmarks, so there is a gap when the car stops short of your desired level, or do the tickmarks reflect a lower charge level?

I have noticed the latter the past couple of months on my vehicle. Example: I set my desired charge to 80% aka the second tickmark from the right. Charging finishes at 77%, but there is no gap between the charge level and the 80% tickmark.
I will check next time I charge. I charged to my normal 90% last night.
 
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