NEW PCS (Power Conversion System) Failure & Replacement News

[cyberHoward]

I am trying to follow this issue. My AWD Founders CT was delivered April 12, 2024 with a 3735 VIN. It sounds like it was in the heart of this issue. I see a voluntary recall on Inverter parts, which my truck does not show up on the VIN lookup. I asked about the PCS and the Inverter on my last service appointment and they said there were no issues for my specific CT. I had a couple of Failure not restart and charge notifications early morning while the CT was sitting charged. They indicated that I was going through firmware update during the logged notice and that was likely the issue.

I do not have charging limit issues at home nor on the road where I see as high as 250+. What should I ask about next time to avoid any future issues. I am currently at 21,000 miles.

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[Gigahorse]

Exactly, I'm driving coast to coast with the family this summer, and for the first time, I'm nervous about doing it with a Tesla. Only a 10% chance of being stranded hundreds of miles from a service center, needing a part that's back ordered a few weeks...awesome. That'll cost me thousands in hotel stays missed, fingers crossed they don't charge me 7 grand for the repair!

2,800 miles from home, PCS bricks, just stay in a hotel near the service center for 6 weeks, or rent a car and continue your trip, then fly out when your truck is finished.

Seems to be the Tesla response to this.................

 

[Leifmb]

Why would you guess that?
They were using Rev E in April 2025

I thought, by what I’ve read, Rev G was started in 2024!

 

[nevetsyad]

2,800 miles from home, PCS bricks, just stay in a hotel near the service center for 6 weeks, or rent a car and continue your trip, then fly out when your truck is finished.

Seems to be the Tesla response to this.................

We're doing a big 10K mile loop around the USA over 4 weeks. I'm really worried that that is Tesla's response if it happens

 

[Leifmb]

We're doing a big 10K mile loop around the USA over 4 weeks. I'm really worried that that is Tesla's response if it happens

If the PCS fails the usual way, you WILL STILL BE ABLE TO SUPERCHARGE. What breaks is the AC to DC Converter, what is used at “home”’chargers/level 1&2.

 

[flamaest]

should be free, and should be a recall. Tesla, don't put junk into our 100k trucks which fails right after the warranty expires. sheesh. sounds like another BMS-a079 model 3 fiasco all over again.

 

[nevetsyad]

If the PCS fails the usual way, you WILL STILL BE ABLE TO SUPERCHARGE. What breaks is the AC to DC Converter, what is used at “home”’chargers/level 1&2.

I mean, it takes out other components when it fails some times, that's why it can be 6 or 7 grand to fix. If we're lucky, it'll charge slow on AC, and that's it. But still, at that point, I'm rushing to a service center. Don't want it to get worse and cause more damage, stranding me longer.

 

[Leifmb]

I mean, it takes out other components when it fails some times, that's why it can be 6 or 7 grand to fix. If we're lucky, it'll charge slow on AC, and that's it. But still, at that point, I'm rushing to a service center. Don't want it to get worse and cause more damage, stranding me longer.

There are 2x 24AMP AC-DC converters. If one fails, the AC (home) charging will be limited to 24 amps. If both fail, then only DC (Supercharger) charging would be available.

 

[mongo]

I thought, by what I’ve read, Rev G was started in 2024!

Nah, I think you are referencing the drive unit inverter recall. That's a completely different thing.

If the PCS fails the usual way, you WILL STILL BE ABLE TO SUPERCHARGE. What breaks is the AC to DC Converter, what is used at “home”’chargers/level 1&2.

There are 2x 24AMP AC-DC converters. If one fails, the AC (home) charging will be limited to 24 amps. If both fail, then only DC (Supercharger) charging would be available.

Many people with total PCS failure have reported Supercharging also stopped working (even though it should theoretically be independent)

 

[Leifmb]

Nah, I think you are referencing the drive unit inverter recall. That's a completely different thing.




Many people with total PCS failure have reported Supercharging also stopped working (even though it should theoretically be independent)

I guess it would depend how the PCS unit fails as it’s not the unit that handles the DC supercharging, I THINK.

 

[Gigahorse]

We're doing a big 10K mile loop around the USA over 4 weeks. I'm really worried that that is Tesla's response if it happens

When was your truck made (sticker inside the driver's door)
If it was pre May 2024 I would do some good deeds between now and then.......

 

[JCERRN]

Why would you guess that?
They were using Rev E in April 2025

Heres hoping my Rev-E holds up… I'm at just over 5k miles on it and I've had only 1 reduced charging event. I mean to be clear- i will be more likely to time out my warranty than to mile out. I only drive 9-10k miles/year as of now

 

[mongo]

I guess it would depend how the PCS unit fails as it’s not the unit that handles the DC supercharging, I THINK.

Right, the PCS sits across the Supercharging contactors (with ACJB between it and them) so it's likely not much in play during DC fast charging. Other than reporting it's health to the main charge controller.

 

[Leifmb]

Heres hoping my Rev-E holds up… I'm at just over 5k miles on it and I've had only 1 reduced charging event. I mean to be clear- i will be more likely to time out my warranty than to mile out. I only drive 9-10k miles/year as of now

If you've had a "reduced charging event" that is a sign of pending failure. I'm guessing your home L2 charger charges at MORE than 24 Amps so BOTH PCS converters are in use. One of them starting to fail would REDUCE your HOME charging RATE to only 24 Amps and set off that error/warning.

 

[JCERRN]

If you've had a "reduced charging event" that is a sign of pending failure. I'm guessing your home L2 charger charges at MORE than 24 Amps so BOTH PCS converters are in use. One of them starting to fail would REDUCE your HOME charging RATE to only 24 Amps and set off that error/warning.

I asked Service and they said since it was only a single event, this did not amount to a PCS failure since everything was still passing checks in toolbox.

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