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MegaEV
Workshop Diary

Real Tesla repairs from our workshop

What came in, what we found and how we fixed it. A look at the jobs we see every day as an independent Tesla specialist.

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.

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The rear drive unit of a Tesla Model 3 sitting in its subframe on a workshop table, with its coolant hoses and wiring attached

· 4 min read

Tesla Model 3 rear drive unit bushings: tracking down a thud from the back

Booked in for a health check, this Model 3 gave itself away within metres with a heavy thud from the back. The culprit was worn rear drive unit bushings: a cheap part, but a big job that means dropping the subframe.

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A Tesla Model S P100D with its bonnet open, connected to an AC service station and gauges in the MegaEV workshop

· 4 min read

Tesla Model S P100D AC and thermal system overhaul: why a regas is never the whole answer

A P100D came in with radiator shutter alerts and weak air conditioning, despite a recent regas. A high-pressure nitrogen test found leaks a vacuum test had missed. Here is the full overhaul, and why we now test every AC system under pressure.

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A Tesla Model 3 radiator pack removed from the car, with leaves and road debris covering much of its surface

· 4 min read

Tesla Model 3 heat pump compressor failure: why one failed part can become a £3,000 to £5,000 repair

A Model 3 arrived with ‘Air Conditioning Unavailable’ and no cabin cooling. A failed heat pump compressor had contaminated the whole refrigerant system. Here is the full repair, and what owners can do to give the heat pump the best chance of a long life.

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A red Tesla Model S on the new four-post alignment ramp at MegaEV, with the Hunter HawkEye Elite cameras and wheel targets in place

· 2 min read

Major workshop upgrade: a Hunter HawkEye Elite alignment ramp, a clear-floor lift and a battery platform

After two busy weeks, our workshop upgrade is finished. A clear-floor two-post lift, a dedicated battery removal platform, and an in-house four-post alignment ramp with a Hunter HawkEye Elite system.

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Three stages of the Tesla Model X charge port repair: the corroded connector, the same connector cleaned and restored, and the chassis area around the drain beneath the charge port

· 2 min read

Tesla Model X charge port fault: stranded at a Supercharger, charging again the same day

A Model X owner was stuck at the Heathrow Supercharger when the charge port stopped working. We found water damage from a blocked chassis drain, saved the original charge port, and had the car charging again within hours.

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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.

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The large drive unit of a Tesla Model S partly dismantled under the car, with the motor housing open during the coolant delete

· 2 min read

A complicated Tesla Model S coolant delete: solving seized high-voltage cables

A 2017 rear-wheel-drive Model S had coolant in its large drive unit. The coolant delete turned complicated when the motor's high-voltage cables were seized. Here is how we found the room to work and saved the drive unit.

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Three stages of the air strut refurbishment: the corroded lower collar, the old seal in place, and the collar cleaned up and ready for new seals

· 2 min read

Tesla Model X Raven air strut refurbishment: saving the original strut

A Model X Raven came in with a heavy air strut leak. The shock absorber inside was healthy, so we refurbished the original Tesla strut instead of fitting a new or aftermarket one. Here is what usually causes the leak, and how we fix it.

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