Tesla Model S -- High Voltage Battery Problem :(

Tesla Model S -- High Voltage Battery Problem :(

Took the car in for service , after the software upgrade, (that very day), the car had a message ' car needs service, may not restart '

It was towed away.

Were told it is high voltage battery problem. Service person said it could be latest rains ?

Has anyone experienced this before?

I must say, Tesla service is very nice. I sure hope the car is not a lemon though.

Gizmotoy | 03. helmikuu 2014

A small number of people have had failures in the high voltage battery and have had them replaced with remanufactured units. I'm sure the service person was just trying to be helpful, but suggesting some rain killed the car isn't exactly confidence-inspiring, that's for sure.

Let us know how it turns out. If they do replace your battery, I'd be interested to see what revision you get (A through D, currently), which is noted behind the front passenger wheel.

hillcountryfun | 03. helmikuu 2014


Is this a placard that you can see after you open the passenger door?

Thanks -

zwede | 03. helmikuu 2014

No, the battery label is under the car. Easy to see as long as you lie down on the ground. Look at the underside of the floor just behind the passenger front wheel and you can't miss it.

nickjhowe | 03. helmikuu 2014

@hillcountryfun - no - it is in the wheel well. You need to pretty much lie on the floor and look up inside the back of the front passenger wheel well.

hillcountryfun | 03. helmikuu 2014


Joshua Burstyn | 03. helmikuu 2014

Hi SMinnihan.

I'm not sure why you posted the above video. It appears to show the results of a bad 12V low-voltage battery... not anything to do with the high-voltage pack.

DallasTxModelS | 04. helmikuu 2014

I can't read or understand the native language used in the video but the large warning on the big screen says 12v battery not high voltage battery and yes the Model S will not start with a dead 12v battery.

lcheema | 06. helmikuu 2014

Still not fixed ... Tesla is still reviewing the data

AmpedRealtor | 06. helmikuu 2014

SMinnihan is a notorious troll in these forums, posting anything negative that can be found about Tesla and Model S while blindly promoting BMW and it's i3. There is definitely an agenda at work. Have a look...

Tâm | 06. helmikuu 2014

What a coincidence for the high voltage failure AFTER a software upgrade?

Does the software do something to the battery pack?

Pungoteague_Dave | 06. helmikuu 2014

@gizmo - they don't use remanufactured units when replacing batteries. My low and high voltage batteries were replaced at the same time. The service advisor made a big point of saying the new batteries and the replacement wiring harness had the latest design updates (my original A battery became a B at that time). I asked whether they ever use remanufactured and they said "no" because the warranty is on new items - would you let any manufacturer replace a warranty part with a used part? Warranties require new parts.

EV Quorum | 06. helmikuu 2014

Same thing happened to my battery at 5,000 miles. During a supercharge session far from home. Made it home without incident after consolation with hotline. Battery was replaced, no more problems since.

If you don't mind, a lot of people here would like to get as many details as you can about your battery replacement service. How long (labor hours) does it take? What has to be done to complete the repairs (i.e. coolant flush, firmware upgrade to support replacement battery, etc.)

You might also want to personally inspect all the nuts and bolts before the car comes off the lift (can discuss offline if you're interested).

Since there's been a bit of debate here about whether different models have different underbody configurations, you're popularity will soar if you post some good photos, especially if you can get any mid-operation pix that show the high and low voltage connections and coolant lines. Mine was put together before I could get any of the topside.

AoneOne | 06. helmikuu 2014

I had a similar battery failure. It turned out to be a misplaced seal on the main battery power connector that allowed water into the connector. They towed it about 200 miles to the closest service center where they "dropped the battery" to correct the problem.

Not every battery problem requires battery replacement.

EV Quorum | 07. helmikuu 2014

Excellent info, thanks for posting @AoneOne.

civi | 03. kesäkuu 2014

@Icheema: Hi, I think the problem is due to the bad voltage regulator with the alternator that is causing the high voltage battery problem because it is not able to control the voltage generated by the alternator.

Car t man | 04. kesäkuu 2014

The car has no alternator. The drive motor is the alternator. You may be referring to the DC DC unit, which converts DC volage from the main
battery voltage pack to 12v.

jinglehyme | 23. kesäkuu 2014

Mine was just replaced with a remanfactured unit. I'm pissed. See thread Road Service Sadness -

jinglehyme | 23. kesäkuu 2014

You can look at the part number on your receipt - the letters REMAN will be in the part number. They told me it was new. Wrong!

Red Sage ca us | 23. kesäkuu 2014

New... to you?

jinglehyme | 23. kesäkuu 2014

Nice Try!

David Trushin | 23. kesäkuu 2014

So what. It under warranty same as new.

Red Sage ca us | 23. kesäkuu 2014

I'm really just saying... In my guise as a Certified Tesla Motors Apologist Fanboy... That the company that sends sheet metal in one end of a factory and drives cars out the other end... A company that literally assembles every aspect of a battery pack on site themselves, not farming them out to someone else... Is probably a bit more adept than other manufacturers would be at providing viable, usable, reliable 'remanufactured' components.

That is, if their own internal engineers are satisfied with the characteristics of the battery pack, it will likely far surpass your actual needs. Reportedly, there is a guy who repairs battery packs in the Toyota Prius by replacing the individual cells by hand for all of three hundred bucks. No one has any complaints about his work, as it revitalizes a dead Prius battery pack allowing for years more service. Somehow I'm rather certain that Tesla would do a better job than anyone else to provide you a 'new to you' battery pack.

jinglehyme | 23. kesäkuu 2014

More like my old one that failed.

Red Sage ca us | 23. kesäkuu 2014

I... don't think so. Tesla has been known to ship failed components back to the factory for inspection. The Service Center may have had a backup battery pack on hand, in storage, on the shelf, that happened to be refurbished, certified, and cleared for use in another car. New as the day it was born, so to speak. If you literally feel you deserve an absolutely brand, spanking, new battery pack, fresh off the line -- make sure that Tesla is aware of that requirement. But be prepared to wait -- a while - to get it.

jinglehyme | 23. kesäkuu 2014

No - they just should have been up front about the language they used. New is new, and can only be sold as new. Refurbished is another animal altogether. And it does matter to me. Not only was I was not given a choice but I was led to believe that I was getting a new battery.

Red Sage ca us | 23. kesäkuu 2014

If the component was replaced under warranty, and you were not charged for it, then it was not 'sold'... Most state & federal laws allow a remedy under warranty to be 'within manufacturer's specifications' for replacement... That is, something that is literally 'new' or 'equivalent to' the item being replaced. Tesla Motors may, at their own choosing, see fit to remedy the situation in any way that meets your needs as a Customer... But that would be above and beyond the letter of the law, in my opinion.

Captain_Zap | 23. kesäkuu 2014

I believe refurbished and remanufactured is two different things.

AndyO | 23. kesäkuu 2014

+1 Red Sage
I trust Tesla. If they replace a component in my car and it remains under warranty then I'm satisfied. I don't know of any warranty that gives you a new replacement *AND* renews the warranty to the time of the replacement. Try that with any regular 12V auto battery. Some only give you one replacement and then you're on your own.

AmpedRealtor | 23. kesäkuu 2014

jinglehyme, if it's any consolation I thought I read somewhere that the REMAN packs are totally rebuilt at the factory and meet the same specifications as new. Have your tried a range charge to check the capacity?

jinglehyme | 24. kesäkuu 2014

It charges to 260.

AmpedRealtor | 24. kesäkuu 2014

Is that better or worse than the battery it replaced?

Bighorn | 24. kesäkuu 2014

Let's not let facts get in the way of emotions.

mrdaniel | 24. kesäkuu 2014

260 sounds reasonable. Someone reported their full charge at 75,000 miles was 246 which is over 7%, so ~1% per 10,000 miles. 260 for a car with 20,000 miles is about right.

jinglehyme | 24. kesäkuu 2014


Actually a little better capacity, but not full capacity - I can live with it.

My new focus is dealing with the insurance company for the little old lady who just used my rear bumper as means to fit her car into too small of a space! Karma for thinking bad things about Tesla - you decide.

J.T. | 24. kesäkuu 2014

@jinglehyme I really appreciate you sharing this experience here. A lot of people can take a lesson from you on how to report and deal with a very frustrating problem. I hope your future with your car is as smooth as it's acceleration. (After the body repairs, of course,)

daniel | 13. marraskuu 2019

I am buying a Tesla Model S60 rfom 2014, and apparently it got its battery replaced. Now, I am not sure if it is the entire battery that gives the power to the car, or something else. I need your help ladies and gentlemen to fully understand this issue:

This is the information from the invoice from August, 2019:
Bekymring (Issue): Customer states Tuesday, August 20, 2019 - 18:14:15 CEST vehicle has multiple alerts that it has reduced power.

Performed diagnosis. Replaced HV Battery, air purge twice and firmware update. Tested and validated positive after repair

Utført arbeid (job done): General Diagnosis
Utført arbeid (job done): Replace 100 kWh HV Battery

Deler som er skiftet eller montert (parts that have been replaced and mounted):

Does it mean that this Tesla Model S60 has now a 100 kWh batterypack inside, same as the new Model S use today, or did they just remove a plug or something. I am referring to the part number 1120019-01-C in this repair order.

Thank you very much for your help!

Daniel | 13. marraskuu 2019

@daniel - It does appear they replaced it with a 100 kWh battery. The pryofuse wasn't used on smaller batteries, only the 100 kWh battery. Now, Tesla, will software limit the battery to act like a 60, but that's a good thing. The battery should last far longer than a physical 60 battery. I wasn't aware they did this, but it saves Tesla from inventorying a bunch of different size batteries, especially for Europe. The small downside is the car is a bit heavier - probably not enough to notice.

You might also ask how much it would cost to unlock additional capacity. For a while, it was something like $2500 Euros to make a 60 into a 75.

daniel | 14. marraskuu 2019


Thank you for your information. So it really means it is a 100 kWh battery.
I understand that this is only a refurbished or remanufactured 100 kWh battery, so its capacity is probably lower than 100%. In what way would the battery last longer than a psyical 60 battery?

I am trying to find out if it is possible to upgrade the software so I can upgrade 60 to 75. But the owner can not see this in his Tesla account. And the service can not tell me as I am not the owner.
I am trying to find out about this cost. And, according to other posts Tesla would change your tag on the car from 60 tp 75. Can you verify this?

Thanks again!

daniel | 14. marraskuu 2019

Also, what is the pyrofuse?

I could not find the part number in

murphyS90D | 14. marraskuu 2019

It's a pyrotechnical fuse.

I doubt that is the one Tesla uses.

It provides a millisecond disconnect of the battery when necessary.

Bighorn | 14. marraskuu 2019

And this is a problem?

I've never heard of such luck. Didn't even think is was physically possible to upgrade a 60 to 100 kWh. The rated range should make it pretty simple to figure this out. They definitely replaced the fuse. The question remains whether they replaced the battery pack. It says at the beginning they were going to, but it's not in the parts list.

daniel | 14. marraskuu 2019

Yes, that is what I think as well. That the only replaced the fuse.

ronnie.stronge | 22. marraskuu 2019

I have just returned from holiday - a week in the warmth - to a cold English airport car park and my 2.5 year-old Model S with 25000 miles done. I expected 100 miles+ to show but only 52 miles showed. The temperature could have dropped to near 2degrees C while I was away. Was the difference likely to be due to the cold, my miscalculation/ assumption the 100 miles or my wife leaving her heated set on when we left ? A SC fill-up within 15 miles meant we got home safely but checking out a possible technical issue or my fading brain persists !!