" . . . it is the Tegra daughterboard that Tesla charges $120 for. Total cost, including labor, is closer to $400."
Wait a minute. If Tesla sells the daughterboard for $120 it should cost them somewhere between $12 and $60. Normal mark-up for parts between manufacturing and end user are 100% or more.
Labor is what? About 2 hours? (I really do not know) that would be $40 to the mechanic and about the same in payroll expenses, add $10 per hour for the shops space = $100 total labor. So total cost to Tesla per replacement is more like $150 or so. Also not all 158,000 cars manufactured with this defect are still on the road, and many have surpassed the 100,000 miles mark.
My guess is 50,000 actual warranty repairs at a cost o $150 each = $7.5million.
That is how I see this, no big deal.