$500 core charge? It seems they really want the old one to keep having remanufactured ones, which probably means that they don't have a supply of new ones and don't have a way to substitute with MCU2.
Another unique experience of owning a Tesla vs. a traditional car manufacturer which supplies
new parts for years and after that aftermarket parts are also available.
With some types of ASICs such as commodity CPUs, it is very difficult to get a new batch made after the initial production has stopped. The chip fabs introduce new manufacturing processes that produce chips that are totally incompatible with the prior chips (voltages are different, timings are different, etc).
On the one hand, the NVIDIA chips were probably made in very large volumes and so there are probably lots of spares floating around, on the other hand there may be other support chips on the board that aren't as easy to get; if tesla wasn't planning on this board having a high failure rate they may simply not have banked enough parts to maintain a reasonable supply of parts. It would probably be completely impossible (IE absurdly expensive, not actually "eat-a-neutron-star-sandwich" impossible) to make a brand-new iphone 3gs using only parts manufactured in 2019, for example, because there are too many highly integrated parts for which there are no manufacturing capacity.
We will very soon know how diligently they've been refurbishing these MCU1s -- the continuum is anywhere from
- ship untested returns to other customers, repair boards that come back two times
- drop off a batch of dead MCUs and ebay bought eMMCs at a San Bruno phone repair place that will drop ship the fixed boards to service centers
- send boards off to an aviation electronics specialty shop that re-certifies the part after putting it through extensive testing including vibration, wide temperature ranges, and finally x-raying the boards
If there is a large return rate on replaced MCUs, they're taking options 1 and 2...
As far as other car manufacturers goes -- they tend to farm out the actual manufacture of a part to other companies (delphi, delco, bosch, etc) and those companies tend to focus on producing a stable family of products used to integrate into a wide range of cars and so they have an incentive to have a small family of stable products to drop into different OEM requirements. This approach results in lower integration density and less optimization but a slightly more stable supply chain.
At some point Tesla will need to address legacy support. They will face a variety of issues that taint the brand, things like MCU failures, battery degradation, etc. They can either walk away Nissan style or $tep up like Lexus or Mercedes. Time will tell.