@Guy V @Droschke @Chaserr
Lets revisit this since you disagree:
@raphy3 said "The quickest thing to do would be to yank the bad modules and remanufacture the battery with the rest of the good modules as one level lower battery, and use it for warranty repairs of vehicles with smaller batteries. So, 75, 70, 60... and even 40"
There are two situations in this overall.
1. the 16th module is bad, leaving 15 good modules
2. Tesla currently uses packs with either 16 modules or 14 modules.
Without having to do crazy logistics and special BMS firmware they have two choices
A. grab a usable module from another pack and replace the 16th module to have 16 total. This is what WK057 said wasn't doable. He said something to the effect that the pack would be out of balance no matter how hard you tried to find a matching module and it'd be right back into the same limited situation very quickly.
B. take out one bad and one good module out and put 2 dummy modules in to convert the pack to a lower capacity. This could be done but turns a 85 pack into a 60 and wouldn't be quick or easy.
So if you look at a list like 85, 75, 70, 60 it won't just step down one place on that list. It'd drop multiple places on the list.
Neither of these are things WK057 does on a regular basis. What he does is swap entire working packs or tear down the pack and sell loose modules for use NOT with a tesla but somewhere else like a home system or a custom conversion of a non Tesla.