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High-Voltage Battery Diagnostics & Repair

Tesla high-voltage battery repair in Surrey

The high-voltage battery is at the heart of every Tesla. When a battery fault appears, accurate diagnosis matters more than anything, because the difference between a repair and a new battery is often thousands of pounds.

call020 8064 3227

verified_user1-year warranty on parts, from the invoice date

A Tesla Model S high-voltage battery pack opened up for repair in the MegaEV workshop

What we can do

  • Fault diagnosis: BMS warnings, isolation faults, reduced power or range, and charging problems.
  • Battery health assessment: a clear picture of the battery's condition, before you buy, sell or commit to a repair.
  • Battery repairs: where the fault is in a part of the pack that can be repaired, we repair it instead of replacing the whole battery.
  • Battery heaters and related components: faults that often start small but escalate quickly.
  • Battery replacement and upgrades: for Model S and Model X, including upgrading a Model S 85 to a 100kWh pack.

We can repair or replace batteries for Model S and Model X. We do not repair Model 3 batteries, but we can replace them, depending on availability and compatibility.

Repair, not replace, where it makes sense

A battery warning does not automatically mean a new battery. A Model S 85 with a BMS voltage fault came to us facing that prospect. We traced the fault to one module and repaired the pack instead. Another Model S had a high-voltage battery heater fault, and with genuine Tesla heaters in stock, it was back on the road the same day.

Sometimes the fault is not where it seems. A Model S 85 arrived with coolant pouring from the battery connector, and the real problem turned out to be how the pack had been refitted after a repair elsewhere.

Equipped for battery work

Our workshop has a dedicated battery removal platform, so when a pack has to come out, it comes out safely and properly. Our technicians hold IMI Level 2, 3 and 4 qualifications in electric and hybrid vehicles, and we use Tesla Toolbox 3 for diagnostics.

A clear plan before any work

Battery problems can be complex and expensive. We carry out a thorough diagnostic assessment first, explain what we have found in plain English, and recommend the repair that suits the car and its condition. If you are weighing up a repair against selling the car, we will tell you honestly what we think.

Workshop Diary
All diary entriesarrow_forward
A Tesla Model S high-voltage battery heater with its orange high-voltage cable, removed from the car and lying on the workshop floor

· 3 min read

Tesla Model S isolation fault: tracing an intermittent problem to the battery heater

A Model S showed "Vehicle may not restart" at a Supercharger, with isolation and fast-charge contactor alerts. The heater passed its thermal test, but the journey logs and an insulation test found the real fault, and the contactors did not need replacing.

Read morearrow_forward
The high-voltage battery pack of a Tesla Model S 85, opened up in the MegaEV workshop with all its modules visible

· 3 min read

Tesla Model S 85 BMS voltage fault: repairing the battery instead of replacing it

A Model S 85 came in with a BMS over- and under-voltage fault. Here is how we traced it to one module, why the pack had to come out, and how we repaired it without a new battery.

Read morearrow_forward
A red Tesla Model S in the MegaEV workshop with its bonnet open and the battery heater units on the floor in front of it

· 2 min read

Tesla Model S HV battery heater replacement: fixed the same day

A Model S came in with a high-voltage battery heater fault. It was still driveable, but faults like this escalate quickly. With genuine Tesla heaters in stock, we replaced it and had the car back on the road the same day.

Read morearrow_forward
A new and a damaged Tesla Model S battery coolant rapid mate connector side by side on the workshop floor

· 2 min read

Tesla Model S 85 emergency coolant leak: when the real fault is a previous battery refit

A Model S 85 came in with coolant pouring from the battery's rapid mate connector. The leak was only the symptom. The real problem was how the battery pack had been refitted after a repair elsewhere.

Read morearrow_forward
Two Tesla Model S battery packs on trolleys outside the MegaEV workshop, with a grey Model S parked by the door

· 2 min read

Tesla Model S 85D to 100kWh battery upgrade: more range, faster charging, free Supercharging kept

Our own low-mileage SC01 Model S 85D has had its original 85kWh battery replaced with a 2023-spec 100kWh pack. Here is what the upgrade brings, and why the car keeps its free Supercharging.

Read morearrow_forward

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Prefer to call? 020 8064 3227, Mon to Fri, 8am to 5pm. Our lines are often busy while we work on cars, so a message is usually quicker.