PCS failure rates by year...is it just a matter of time?

[Jager]

You're proposing absorbing a second new-car-depreciation hit, for essentially the same vehicle, in order to get a fresh warranty.

I'd suggest keeping your present CT and even if you ended up having to pay out-of-pocket for some future PCS failure, the cost to do so would be far less than the second depreciation hit. You're essentially self-insuring against that future failure.

It might be different if we had data that showed Tesla has fully solved the PCS failures. Alas, those failures have been happening for many years, across Tesla's lineup, and I don't think we've seen anything to suggest that newer vehicles and/or the latest part numbers have addressed it.

You'd be throwing a lot of money at a hope and a prayer.

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[CyberTexas]

Fixing PCS cost how much out of warranty??

 

[Coagulation]

Fixing PCS cost how much out of warranty??

I recall a forum member here spend around $7k

 

[CyberTexas]

The way I am driving…30k miles per year and supercharging everyday, maybe I will kill the PCS before factory warranty goes out??

 

[Floridaman]

I recall a forum member here spend around $7k

Yes. It cost me 7k..

 

[Coagulation]

Ultimately I’m just hoping for an extended warranty option like other models have. Hopefully sometime in the next 2 years they get that going

 

[Known-Background]

I think we all need to file nhtsa especially those that had the issue. Grok says 40% of owners are having issues… https://www.nhtsa.gov/report-a-safety-problem

We could end up stranded in unsafe conditions if our vehicles won’t charge while traveling. We shouldn’t be waiting to either fix it free after it happens or pay $7-6000 dollars when it happens after warranty. Sounds like it’s not an if but a when situation.


My truck hasn’t failed yet, but I’m genuinely concerned it might. I’m hearing from a lot of other Cybertruck owners that their Power Conversion System has failed, and now that people are getting past the 50,000-mile warranty mark, repairs are reportedly costing over $6,000.

From what I understand, when it fails the truck suddenly can’t charge, which essentially makes it unusable. That’s what worries me most. If this happens at 50,001 miles, you’re suddenly responsible for a $6,000 repair on what appears to be a known issue.

I’m getting close to that mileage, and I’ve seen reports of failures happening anywhere from 5,000 miles to much higher. It makes me uneasy knowing this could happen at any time or even worse wrote after my warranty ends!!!

I honestly wish there were a way to proactively test or address it before the warranty expires.

Does this seem like something that should qualify as a recall if it’s a known issue that renders the vehicle unable to charge and effectively unusable? What would you recommend?

 

[JCERRN]

I recall a forum member here spend around $7k

Roughly $1700-$7000. Not sure why such a huge gap.

 

[JCERRN]

The way I am driving…30k miles per year and supercharging everyday, maybe I will kill the PCS before factory warranty goes out??

Maybe. That is a moderately heavy duty cycle. The thing is, pcs is not a wear item. It shouldnt “wear out” with use. If it fails, its because of a manufacturing defect or an oem design flaw. Many have posted part numbers with different revisions after replacement, indicating that T is quietly addressing the issue in the background. But yeah this should not be happen and T should good will any pcs failure under drivetrain warranty imo.

 

[CyberTexas]

I have read on Grok that the gap in cost to replace PCS is because of what else is damage in addition to PCS because of PCS failure??

SO THEN, is it financially smart to replace the PCS now BEFORE failure. Eat up approximately $2000 now to get the updated PCS version and call it a day??

It would prevent costly repairs after warranty and, of course, prevent being stranded. Not saying $2-3k is chump change but it may prevent future headaches?

I may do this right before factory warranty runs out if PCS has not gone bad.

 

[CyberGus]

To have any idea what our chances are, we need someone with a replaced PCS to mail the failed unit to Munro

 

[mongo]

I think we all need to file nhtsa especially those that had the issue. Grok says 40% of owners are having issues… https://www.nhtsa.gov/report-a-safety-problem

We could end up stranded in unsafe conditions if our vehicles won’t charge while traveling. We shouldn’t be waiting to either fix it free after it happens or pay $7-6000 dollars when it happens after warranty. Sounds like it’s not an if but a when situation.


My truck hasn’t failed yet, but I’m genuinely concerned it might. I’m hearing from a lot of other Cybertruck owners that their Power Conversion System has failed, and now that people are getting past the 50,000-mile warranty mark, repairs are reportedly costing over $6,000.

From what I understand, when it fails the truck suddenly can’t charge, which essentially makes it unusable. That’s what worries me most. If this happens at 50,001 miles, you’re suddenly responsible for a $6,000 repair on what appears to be a known issue.

I’m getting close to that mileage, and I’ve seen reports of failures happening anywhere from 5,000 miles to much higher. It makes me uneasy knowing this could happen at any time or even worse wrote after my warranty ends!!!

I honestly wish there were a way to proactively test or address it before the warranty expires.

Does this seem like something that should qualify as a recall if it’s a known issue that renders the vehicle unable to charge and effectively unusable? What would you recommend?

NHTSA does not seem to me to be the correct agency to report to as a PCS failure does not impact highway (versus personal) safety. It's the EV equivalent of having a stuck gas cap and running out when your fuel gauge still works.

If it caused the truck to lose power when reporting 25% that is covered by regulations and would impact road safety.

State Attorney General consumer protection agency might be more appropriate.

 

[Jhodgesatmb]

I recall a forum member here spend around $7k

There appears to be a range even on our forum, from about $3,700 upward. I have no idea why the range. When I picked my truck up I asked how long it took and what they had to open up. They had to open the bed up and the labor took 5 hours. I am assuming half to get in and half to get out. That means the part is also expensive.

 

[Gundo]

Well, I did exactly what you are proposing.
Picked up my current FS AWD CT on May 1, 2024.
My current VIN is in low 4000s, have 34k miles and never a serious problem - though 50k miles is coming up fast and PCS failure is a legit concern
I really have loved my truck more than any prior car except my 997S

So I went through order process, and got what I consider a solid trade in value, plus financing is now 2.99%

But truly, the FSD Transfer pushed me over the edge.

Anyway, my new VIN is in the 90,000s and I pick it up Mar 18
Looking forward to all the improvements over 2 years

As a bonus, this entire adventure got me to shop insurance as well.
Progressive ($1,000 deductibles, Full Glass) will save me $2,400/year over GEICO, if you can imagine.

 

[Jhodgesatmb]

NHTSA does not seem to me to be the correct agency to report to as a PCS failure does not impact highway (versus personal) safety. It's the EV equivalent of having a stuck gas cap and running out when your fuel gauge still works.

If it caused the truck to lose power when reporting 25% that is covered by regulations and would impact road safety.

State Attorney General consumer protection agency might be more appropriate.

I do not think that Tesla would recall the PCS unless it is a national issue, so what is the federal agency that would pressure Tesla to fix this problem if not the NHTSA? Are they part of the DOT? Ok, I asked a ChatGPT equivalent the following question (after several others):

"Many people have had their Tesla PCS fail. This results in the car being unable to charge (either AC or DC). It could happen anywhere at any time and doesn't fail over time but instantly, so you could be stranded in the middle of nowhere. It is a costly and time-consuming repair."

Here is part of the reply:


The failure of a Power Conversion System (PCS) in a Tesla is a classic example of a "gray area" in federal oversight. Whether it is a safety issue (NHTSA) or a quality issue (State Lemon Law) depends on the specific outcome of the failure.

1. When it is a NHTSA Safety Issue
The NHTSA monitors defects that pose an "unreasonable risk" to safety. A PCS failure could trigger a federal investigation or recall if:

• Motive Power Loss: The PCS is responsible for converting high-voltage (HV) power to low-voltage (LV) power to run the car's computers and safety systems. If it fails while driving, the car can lose propulsion and steering, which the NHTSA explicitly defines as a safety risk.
• Emergency Hazards: If the failure strands you in a dangerous location (e.g., a high-speed highway or extreme weather environment) with no way to move the vehicle or maintain climate control, it may be argued as a safety-related defect.
• Fire Risk: If the hardware failure involves electrical shorts or thermal events during charging, the NHTSA Battery Safety Initiative would take jurisdiction.
  Department of Energy (.gov) +4

2. When it is a State Quality Issue
If the car simply "won't charge" while parked in a safe location like your garage, the NHTSA often views this as a non-safety quality issue, similar to a broken air conditioner or radio. In this case:

• Lemon Law: You would seek relief through your State Attorney General. Most states allow you to demand a buyback or replacement if a "non-safety" issue leaves the car in the shop for 30+ days or requires too many repair attempts.
• Magnuson-Moss Warranty Act: This federal law allows you to sue for damages if a manufacturer like Tesla fails to fix a known hardware defect under warranty in a timely manner.

Summary of Actions

• Report to NHTSA: If your PCS failed while driving or left you in a dangerous situation, file a Safety Complaint to help build the case for a recall.
  
  

As a result, I believe that I did the right thing reporting this to the NHTSA though I acknowledge that Tesla (and possibly the NHTSA) might argue that it isn't a safety issue. I suppose it would matter how many people report it and to which agency. I think the effort would be diluted going through states AGs and would take longer to bubble up.

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