Is Tesla's Structural Battery Repairable?



This is one of our favorite videos, when two respected EV engineers get together, and discuss the new Tesla 4680 structural “Pink” battery pack, whether it is destined for the crusher if it fails, or repairable in aftermarket.

Initial conclusions, after a Munro Live teardown, was that this expensive main battery pack becomes a reclamation project for recyclers if it fails.

This video presents excerpts from a Pete Gruber and Sandy Munro Podcast, in which ideas were discussed, outlining possible repair paths.

#ev #grubermotors #tesla #batteries #elon #pinkbattery #structuralbattery #4680 #munrolive #sandymunro #teardowntitan
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40 thoughts on “Is Tesla's Structural Battery Repairable?”

  1. Great segment- subbed!
    I watch Sandy pretty religiously but have just discovered you guys.
    Trying to soak up as much battery pack info as possible so I can sounds reasonably knowledgeable at the dealer if/when service is required. Those Tesla packs look like a nightmare. Sandy mentioned BMW uses modular packs so I imagine my Mini SE is likely constructed in that style.

    Reply
  2. Tesla is going to hope and rely on their batteries and cells not going bad. If the battery is part of the structure and it needs to be replaced under warranty then I want to know what their process is because their battery might be good but all that pink insulation foam over and in between every cell looks like a nightmare.

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  3. I thought the pink stuff was an expanding foam that would dissolve easily in acetone. When I hear "potting material" I think heavy, gummy, almost solid rubber material. Seems like a strange choice when weight is always an EV concern.

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  4. So the Tesla warranty on its batteries is for a maximum of 8 years or 240,000km or less for some models. That's about the same length of time a battery lasts in an ordinary IC car. So if the Tesla battery modules fail after this time you're going to be up for repair or replacement out of your own pocket. So what is the general cost to repair the battery and what is the warranty for the repair?

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  5. The capacity of a lithium battery pack is defined by its weakest cell.
    Isolating and replacing a bad cell will extend the life of the pack.
    Tesla are fighting the "right to repair", which is very short sighted. They could offer courses on repairs, and proper tools, if they think techs would goof it up.
    Individual cell voltage monitoring is not hard to accomplish, and could be built into modules.

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  6. EU has a law proposal that states the right to repair and will force manufacture to supply spare parts for there products and thus ending the just by a new one mentality and make repair costs more transparent. Is there any one that thinks it is really cheaper to by a new battery pack than to repair it?

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  7. Tesla used to repurpose modules that failed and reuse the good cells into powerwalls. Not sure now with the new 4680 but I imagine development is already underway to utilize those cells as well.

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  8. Afaik the Model 3 battery pack can handle a couple cells going resistive or dropping out of the pack… Therefore it won't fail in the same ways as the old Model S or Model Y packs.

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  9. The tesla pack is structural meaning it takes some of the twisting and bending loads. What is the long term impact on the cells if not the connections. Hopefully it lives up to its warranty or they will have huge costs as the vehicle ages.

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  10. There is nothing funny or to laugh off about repair-ability of the modern EVs. They must be repairable at component level. While I appreciate weight/energy density, it is not a good consumer product that you can't serve.

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  11. Not sure why there is an argument to not make these giant batteries maintanable.

    For everyday people its unrealistic to replace a 20k$ battery.

    There muat be a way to replace induvidual blocks for wear items.

    Batteries will fail eventually but not all at the same time and you can certaily extend the live and or replace pieces to keep it going.

    Imagine having to replace an axel on your car when you need to replace your break pads. It makes no sense.

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  12. I'm sure there is a solvent that can safely be used on this – when handled properly. Not something for a regular repair shop to handle, but there is enough value in those structural battery packs for people with the right expertise to take on.

    Reply
  13. Thanks that was very interesting. it seems that the newer batteries are far more waterproof.
    as rich quoted once, the older style is not that protected. He bought flood damaged cars and the battery was toast.

    On the one hand I like that it is potted but I wish It would be more modular.

    Reply
  14. "Not many at all…" that is a non-zero number, and a single individual can get ruined. If these companies are so sure of the process, they should guarantee the packs, 100%

    Reply
  15. Seems like squirting gunge into the battery pack is hardly a well thought sophisticated approach. Surely they can get similar performance with a method that is far easier to repair.

    Reply

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