I can’t believe it, but the 100 kWh pack, which has been refined from previous generations, has failed on me (and it’s not the cells causing the issue). The problem lies in a flaw we’ve been observing in fossil-fueled vehicles for the past 20 years: aluminum wire bonding. The same problem that TEMIC has failed, either by accident or on purpose, to resolve in the automatic transmissions of VAG and MB over the last 20 years, affecting 80 million vehicles, is now appearing in the 100 kWh battery. The only manufacturer we’ve noticed who has nearly perfect ultrasonic wire bonding is BOSCH, as they adhere to some “secret” recipes for long-term reliability that we observe in the aftermarket. Meanwhile, Temic, Conti, and others continue to make the same mistakes, as does Tesla in this specific case, where they didn’t account for the thermal expansion of the battery module both in width and length, nor the potential galvanization of the “wire sense” flat cable connection. Designing a battery system without any flaws is impossible, but if you ask me, I certainly wouldn’t have failed in these connections, where the wire is too short from the terminal plate to the flat cable used to measure the voltage of one group. All 16 modules in the battery system had 5 to 7 damaged connections, and the ones that suffered the most were those parallel to the longer part of the module (red line), where the expansion was greatest, resulting in the most damaged groups. Based on previous documented cases, which we couldn’t address because they were under warranty, it seems that all 100 kWh batteries will fail between 150,000 and 250,000 km. The good news is that they will never suffer from classic moisture penetration, as they have a new generation of vapor-permeable valves, lack fuse covers on the top side, and don’t have some of the other faults of previous generations (our trade secret). Furthermore, the “batteries” will never fail, i.e., the individual cells, as we estimate that the cells themselves can last over 600,000 km. However, a repair of the entire battery due to unaccounted thermal expansion will likely be necessary, but after that, it will never have this problem again because we fix it permanently!
This 100 kWh battery system has a black metal cover, meaning it is a REMAN battery (already serviced), but the problem has been documented on non-REMAN systems as well. The side effects I’ve noticed include the range dropping overnight more than usual, but this is not a rule. The only clear indication is the drop in BMS parameters by 4 kWh, from 88 to 84 usable. As a result, the range parameter in kilometers on the dashboard decreased after two consecutive charges. A third parameter was visible through measurements with our EVC Explorer tool, where one module showed noise in the voltage measurement. The worst part is that the battery started failing on the highway, but AIDBOX saved the day, acting as life support to get us to our destination. For all other Tesla 100 kWh battery owners, most of whom are still under warranty, an essential battery system service awaits them, which we have only just discovered.
Repair is not easy and cheap, soldering is not possible because it is aluminium (thermal expansion cracks soldering attempts), 10000-15000€ equipment needed beside 40-60 labor hours to finish it. This should not be done by any DIY workshops or any other untrained personel. You risk destroying battery pack.
Error code: BMS_f107, BMS_w177
Affected cars: Model X and S from 2016 – 2021
100D P100D Longrange
Why is Tesla the king of the road? Because it is the only vehicle that enters our garage doors with an average of over 300,000 km and the only vehicle on which we have documented that the ORIGINAL batteries from the first installation exceed 600,000 km. All other vehicles struggle significantly to achieve even half of that, while some EU manufacturers enter garage doors with just 10,000 km (Mercedes, Stellantis, Renault). Thus, Tesla is the absolute record holder where 
Zašto je Tesla kralj asfalta? Zato sto je to jedino vozilo koje ulazi na garažna vrata sa vise od 300,000km u prosjeku i jedino vozilo na kojima smo dokumentirali da ORIGINAL baterije iz prve ugradnje prelaze preko 600,000km. Sva ostala vozila se jako jako trude da bar pola toga uspiju, dok neki EU proizvodjači ulaze na garažna vrata i sa prijedjenih 10,000km (Mercedes,Stellantis,Renault), tako da je Tesla apsolutni rekorder gdje ni dan danas neki Legacy ne uspjevaju “kopirati” Teslin sustav dizajniran 2009 godine. Ali postoji i jedno VELIKO ALI… ALI da bi baterija , iskljucivo Model S i X, prešla 600,000km ona ne smije trpiti dugoročni manji prodor vlage, veliki prodor vode i ne smije biti pregrijana zbog neispravnog klimatizacijalog sustava. Na desetinama uzoraka smo primjetili da su oštecene celije, degradirani moduli i neispravni baterijski sustavi direktno povezani baš sa time. Primjer: jedan baterijski sustav na bloku 1 imao je ostecen ventil, gdje je kroz period od 5-6 godina mala kolicina vlage ostetila modul da je degradirao 5% vise od ostalih i dodatno ostatio wiring sustav na modulu. I tako svi uzorci su ponavljajujuci da je krajnji zakljucak: vlaga je enemy #1 cilindricnim celijama, i da ti baterijski sustavi moraju proci preventivni servis svakih 6-8 godina ili takozvani “RESEALING” proces. Na slikama je demonstracija 3 kriticne tocke a u praksi je oko 10i ostatak je poslovna tajna, jer postoji nedostatak koji je neprimjetan cak i na pressure test procesu. Tako da preporučujemo i Tesla management ekipi da uvede “reseal” u svoju ponudu a svi ostali vlasnici koji žele da im baterija prelazi preko 500,000km prije izmjene obavezno svakih 6-8 godina naprave servis kućišta baterije. Primjer i baterija sa slike gdje prve serije baterije od 2012 do 2015 imaju Fuse Cover sa gornje strane i gdje zbog oksidacije dolazi do ostecenja poklopca. Ovaj je vec pustio vlagu i vodu, i sledeća kiša bi vjerovatno onesposobila bateriju. Takodjer smo primjetili na više uzoraka, da vlasnici koji niti ne znaju da im baterija propusta vlagu na odušcima, su izbjegli oštećenja sustava jako cestim punjenjem na superchargeru ili brzom punjacu, gdje je zagrijavanje baterije i vodova izguravalo vlago vani, gdje je brzo punjenje indirektno pomoglo da produzi vijek baterije ali je povecalo ukupnu degradaciju za 3-8%. U procesu “Resealing” koristimo iskljucivo original dijelove i ne otvaramo poklopac baterije. Jako bitni je koristiti original dijelove i napraviti posao profesionalno jer ako nekad vlasnik odluci otici u Teslu kupiti novu bateriju, oni bateriju staru kad skinu i vide da Fuse cover nije original ili da su koristeni neki drugi ne-originalni dijelovi onda klijentu odbijaju izmjenu. Isto vazi i za izmjenu BMS serijskog broja, tada je zahtjev isto odbijen. Tako da kolegam, ne mjenjajte BMS i koristite original dijelove iz Tesla EPC kataloga.
