So far, it seems to be a loaded dice roll. Especially on S's, they seem to find very minor things to use as an excuse to fail the inspection. I've stopped recommending customers with salvage cars go through with it unless they absolutely must have supercharging and are willing to pay potentially insane amounts to get it.
The biggest issue seems to be that most salvage cars are handled by heavy equipment at one point or another while inoperable. This tends to leave purely cosmetic scrapes and scratches under the car from handling. You'd never even see them normally nor do they matter or affect anything whatsoever. Well, Tesla can disqualify a vehicle from the safety inspection for scrapes on the bottom of the battery pack. These have zero impact whatsoever on safety, but it's an excuse they have in the paperwork for rejecting the car which effectively gives them an out on almost any salvage vehicle they want to reject. We've had customers contact us looking for replacement batteries on perfectly functional cars in order to try and pass this arbitrary inspection Tesla wants. They either want you to pay them for all repair services right then and there ($15k+ for a replacement battery, for example), or you can go elsewhere and pay them to again to re-inspect the car afterwards (another expensive gamble).
To me, I don't think they should be allowed to change anything on a car without the owner's permission, and if the car came with a feature and had it when it was wrecked, it should have it when it's repaired regardless of who did the repair without any hurdles from the manufacturer... but I seem to be in the minority opinion on this somehow around here. I'm also not 100% sure how this is legal for Tesla to do at all (seems almost like extorsion), but IANAL.
