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Tesla Model S Drive Unit Replacement by the Numbers

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During my early days of researching the Tesla Model S, I had concerns about a number of things that were emerging in the press. Fires, Model S drive unit issues, and handling in the snow. Tesla quickly addressed the “firegate” issue by retrofitting the Model S with a titanium shield. My concerns around winter driving, in particular handling in the snow, also became a non-issue after watching several winter driving videos put together by Bjørn Nyland.

Within no time, I became a new Model S owner and quickly learned that driving in the winter could actually be quite fun with a good set of winter tires. Tesla later introduced the all-wheel drive “D” models putting to rest any remaining doubt that the Model S could be the best and safest handling car in the world.

But one question still remains for me, Has Tesla dealt with the Drive Unit issues?

Model S Drive Unit Replacement by the Numbers

There is a group of Model S owners across the forums, but also validated by major publications such as Edmunds, that have had one or more drive unit replacements.

Early reports of drive unit issues ranged from total failures that left the Model S inoperable, to more recent complaints of clunking and milling noises. Elon has said in the past that many of these pre-emptive drive unit replacements were unnecessary and a simple $0.50 shim was all that was really needed, yet Tesla Service centers have been proactively replacing drive units.

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The following polls from TMC show that a majority of Model S owners have had their drive units replaced.

Drive Unit Poll

While the poll only represents a small sample of Model S owners, one might draw significance in the numbers as the density circles around owners needing a drive unit replacement at relatively low mileage, and without any harsh driving prior to failure.

The polls also give insight to the motive behind each drive unit replacement.

Non replaced DUs

DU replacements by build date

 

Though it appears the issues mainly center around earlier versions of the Model S, there’s been reports of newer Model S with Autopilot hardware hearing milling noises coming from the drive unit. One viewer described the sound as “sawing wood”.

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Tesla’s Response to Drive Unit Issues

In typical Tesla fashion, the company acted fast to address the issues, and curb concerns by offering an unlimited mile/8 year warranty on the drive unit. I think this was a great response by Tesla which put to rest any concerns about the quality and long term durability of their drive units.

Elon is now talking about building a power train that will last a million miles and I believe Tesla continues to put significant energy into improving the drive units. Tesla continues to honor the warranty and is proactively replacing drive units that show early signs of problems.

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Tesla-Drive-Unit

 

My Experience

After 12 months of Model S ownership and 30k miles drive, I started hearing a humming noise from the rear of my Model S during highway cruising. The noise was unusual as I had gotten used to hearing only the noise of the tires and wind, but there was a new noise only noticeable when cruising or decelerating with regeneration at 65 MPH and over. The noise continued to become more audible over the next few months, but I learned to live with it and did not contact Tesla. My personal rule of thumb on noise related issues is to wait for passengers to comment on it first. It’s my self crazy check.

Two months after the original drive unit humming noises began, a higher pitched milling type noise started occuring when traveling at speeds of 20 MPH or less. The sound varied depending on how much power was being used. That’s when I reached out to Tesla.

Drive unit details

Tesla service record

 

Tesla service had me come in for a test drive which they can do on demand without you needing to wait. We drove about a block before the Tesla service technician said the drive unit needed to be replaced.

The explanation was that tolerances inside the drive unit have led to metal particles getting into the fluid around the drive unit, and as the concentration of particles increased, it caused the noise from the drive unit to become louder when under load. The new drive units evidently have better tolerances and are less prone to having metal particles being shaved off.

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At that time, Tesla service has been very backed up here in Massachusetts so my appointment for the drive unit replacement was scheduled six weeks out. I put on another 4,000 miles during that wait time, with an increasingly louder drive unit, before it was finally replaced.

When Tesla replaces a drive unit, they replace both the drive unit and inverter as you can see from a copy of the parts list. The last letter in the drive unit part number (“M” in my case) seems to indicate the generation of the drive unit. The later the letter the better, with the “Q”s seeming to have the best longevity according to the forums.

I’m happy to say that I’ve logged 8,000 miles of happy and noise-free driving after my drive unit replacement. The replacement was done recently so my guess is that I have a newer unit, and thus hope this will be my only replacement.

Thankfully for all of us, Tesla has a first class warranty and level of service. While it goes without saying that inconveniences such as this may happen, rest assured that Tesla has you covered and will always strive to make things right.

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"Rob's passion is technology and gadgets. An engineer by profession and an executive and founder at several high tech startups Rob has a unique view on technology and some strong opinions. When he's not writing about Tesla

Investor's Corner

Tesla (TSLA) Q2 2025 earnings call: What investors want to know

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Credit: Tesla Asia/X

Tesla (NASDAQ:TSLA) is set to report its second-quarter 2025 financial results on Wednesday, July 23, after markets close. With this in mind, Tesla investors have aggregated their top questions for the company at its upcoming Q&A session.

The upcoming earnings report follows a mixed delivery quarter. Tesla produced over 410,000 vehicles and delivered more than 384,000 units globally. In the energy segment, Tesla deployed 9.6 GWh of storage products, continuing momentum for its Megapack business. Tesla’s vehicle sales are currently down year-over-year, though a good part of this was due to the Model Y changeover in the first quarter.

Following are Tesla investors’ top questions for management, as aggregated in Say.

  1. Can you give us some insight (into) how robotaxis have been performing so far and what rate you expect to expand in terms of vehicles, geofence, cities, and supervisors?
  2. What are the key technical and regulatory hurdles still remaining for unsupervised FSD to be available for personal use? Timeline?
  3. What specific factory tasks is Optimus currently performing, and what is the expected timeline for scaling production to enable external sales? How does Tesla envision Optimus contributing to revenue in the next 2–3 years?
  4. Can you provide an update on the development and production timeline for Tesla’s more affordable models? How will these models balance cost reduction with profitability, and what impact do you expect on demand in the current economic climate?
  5. When do you anticipate customer vehicles to receive unsupervised FSD?
  6. Are there any news for HW3 users getting retrofits or upgrades? Will they get HW4 or some future version of HW5?
  7. Have any meaningful Optimus milestones changed for this year or next, and will thousands of Optimus be performing tasks in Tesla factories by year-end?
  8. Will there be a new AI day to explain the advancements the Autopilot, Optimus, and Dojo/chip teams have made over the past several years? We still do not know much about HW4.
  9. Cybertruck ramp is now a year in, but sales have lagged other models. How are you thinking through boosting sales of such an incredible product?
  10. When will there be a new CEO compensation package presented and considered for the next stage of the company’s growth?

Tesla will release its Q2 update letter on its Investor Relations website after markets close on Wednesday. A live Q&A webcast with management will then follow at 4:30 p.m. CT (5:30 p.m. ET) to discuss the company’s performance and outlook.

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Tesla Model Y becomes dual champ in China’s vehicle sales rankings

The Model Y’s recent accomplishments suggest that Tesla really has created something special with the all-electric crossover.

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Credit: Tesla Asia/X

The Tesla Model Y was recently deemed a double champion in China, with the all-electric crossover topping two notable sales charts in the country’s automotive sector. 

The Model Y’s recent accomplishments suggest that Tesla really has created something special with the all-electric crossover, as it has continued to outsell even vehicles that are newer and more affordable. 

Tesla China’s announcement

In a post on Weibo, Tesla China VP Grace Tao highlighted that the Model Y topped China’s sales of SUVs, as well as vehicles that are priced in the 200,000-400,000 yuan range. This is quite remarkable, as the Model Y is one of the more costly entries in both lists. She also invited everyone to try out the vehicle for themselves. “You will know the champion strength after a try,” the Tesla VP wrote.

For the first half of the year, the Tesla Model Y sold 171,491 units domestically in China. This number was enough to make it the country’s best-selling SUV and vehicle priced in the 200,000-400,000 yuan range, but it could still easily be higher in the second half of 2025.

This was because Tesla initiated a changeover in Gigafactory Shanghai to shift the facility’s Model Y line to the vehicle’s new iteration. Had Tesla sold the Model Y in full force during the first half of 2025 in China, the vehicle’s domestic sales figures would have been even more impressive.

Model Y L coming

Tesla China’s Model Y sales could see a notable boost in the second half of the year due to the addition of the Model Y L, an extended wheelbase version of the all-electric crossover. Tesla is yet to announce the details for the Model Y L, though the vehicle was listed in the MIIT regulatory catalog as a six-seater. This is game-changing, as the Model Y’s previous seven-seat configurations have caught criticism for being far too cramped and unusable for adults.

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With the six-seat Model Y in the company’s lineup, Tesla would be able to compete with popular vehicles from rivals like BYD, which have made it a point to release spacious three-row vehicles that are designed to carry the whole family. Provided that the Model Y L is priced correctly, it could very well raise Tesla’s vehicle sales this year.

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Investor's Corner

Tesla still poised to earn $3B in ZEV credits this year: Piper Sandler

Piper Sandler analyst Alex Potter maintained his $400 per share price target on TSLA stock.

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Credit: Tesla

Tesla (NASDAQ:TSLA) is still poised to earn about $3 billion in zero-emission vehicle (ZEV) credits this year despite growing concerns over policy shifts under United States President Donald Trump. This is, at least, according to Piper Sandler analyst Alex Potter, who maintained his $400 per share price target and “Overweight” rating on TSLA stock.

Tesla’s ZEV credit revenue

In a recent investor note, Potter acknowledged that Trump’s efforts to undo EV-related incentives could impact Tesla’s ZEV credit income. The analyst noted that these effects would likely not be too drastic, however, even if ZEV credits provide Tesla’s finances with a substantial boost. Last year, Tesla earned about $3.5 billion from regulatory credits, equal to nearly 100% of the company’s FY24 free cash flow, as noted in a Benzinga report. 

Potter estimated that the impact of potential regulatory reversals from the Trump administration will likely not be immediate. “Tesla will still book around $3B in credits this year, followed by $2.3B in 2026,” the Piper Sandler analyst wrote.

Considering his reiterated $400 price target for Tesla stock, Potter seems to be expecting an upside of over 20% for the electric vehicle maker. It should be noted, however, that Tesla is a volatile stock by nature, so huge swings in stock price may happen even without material developments from the company.

Robotaxi developments

The Piper Sandler analyst also highlighted the progress of Tesla’s Full Self-Driving (FSD) program and Robotaxi developments as potential offsets to regulatory headwinds. Potter pointed to expanding operations in Austin and Tesla’s push to launch Robotaxi services in Phoenix and the Bay Area, pending regulatory approval. 

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“In our view, these favorable FSD-related developments are likely to overshadow any/all negative commentary arising from lower 2025/2026 estimates,” the analyst wrote.

In addition to rescinding ZEV programs, the Trump administration has proposed ending the $7,500 federal EV credit by September 2025 and rolling back Corporate Average Fuel Economy (CAFE) standards.

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