NEW PCS (Power Conversion System) Failure & Replacement News

[FarAway]

My truck has been in the Milford CT service center since end of March for the PCS replacement. It was supposed to be finished already. They keep pushing back because can’t get the parts. They now told me the ETA for the part is April 28th. If it actually comes and they fix it; it will be over a month without my truck for this repair. I can imagine any trucks that came after mine or going in now are going to be waiting even longer.

Did they give you a loaner?

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[The Tesla Guy]

Yikes.

Tesla Should Recall the Cybertruck Power Conversion System (PCS)
https://www.notateslaapp.com/news/3989/tesla-should-recall-the-cybertruck-pcs

 

[noobla3]

My PCS was replaced 1/2026 after not achieving 320-500 kw max DCFC

Was that the only reason? You did not have the AC Charging unavailable faults?

How was it logged in the system that you did not charge above 320 kW and how did they diagnose it?

 

[Bri01]

Did they give you a loaner?

Yes. I had to wait a few days for them to get a hold of one, but I was able to get one two weeks ago. But I can guarantee since so many trucks are out, that at this point it will be very hard to get a loaner.

 

[cyberHoward]

I have a 2025 CT with 7500 miles and got the following codes on April 16: HVBATT_a170 (Acceleration and top speed reduced), HVBATT_a056 (Unable to charge), and HVBATT_a742 (Vehicle may not restart). I took the truck immediately to the Chattanooga TN SC and was told that my CT has a PCS failure. It is interesting to me that the codes are all HVBATT codes (I believe the HV battery has an 8 year unlimited miles warranty) but I am told the PCS is not covered under this warranty. I was provided a model Y loaner and was promised a completed repair on May 7. Based on what i am reading, in seems like May 7 is optimistic. I love the CT but I am wondering if I should sell it when I get it back. This is my first post....

I had the same HVBatt error a couple of weeks before I had PCS error. They said it happened during a firmware update and it wasn't a problem, but obviously they were wrong or hiding something. They will replace the PCS in warranty. I am surprised you did not get a PCS2 error and they are replacing it. It will remain under the current warranty until 50k miles. I have the same issue, but nothing is close to this ride, so I am sticking with the CT and hoping version G of the PCS board is good.

 

[waltm]

Thanks CyberHoward. The CT is an amazing ride. The 2024 MY loaner doesn't compare to the CT and I miss driving it.

 

[mongo]

I have a 2025 CT with 7500 miles and got the following codes on April 16: HVBATT_a170 (Acceleration and top speed reduced), HVBATT_a056 (Unable to charge), and HVBATT_a742 (Vehicle may not restart). I took the truck immediately to the Chattanooga TN SC and was told that my CT has a PCS failure. It is interesting to me that the codes are all HVBATT codes (I believe the HV battery has an 8 year unlimited miles warranty) but I am told the PCS is not covered under this warranty. I was provided a model Y loaner and was promised a completed repair on May 7. Based on what i am reading, in seems like May 7 is optimistic. I love the CT but I am wondering if I should sell it when I get it back. This is my first post....

Those aren't PCS codes though. More likely Device Ancillary Cluster.
Which isn't to say there isn't also a PCS issue.
Did you need to go into service mode to read those alerts?

 

[waltm]

No. See attached.

I have concerns that it is not the PCS at all based on these codes. I guess we will see when the repair happens and I get the CT back.

 

[mongo]

No. See attached.

I have concerns that it is not the PCS at all based on these codes. I guess we will see when the repair happens and I get the CT back.

If the PCS DCAC was only partly failed its alerts only show up on service mode (and AC charging would be limited to 24A).
So it can be the PCS has issues also, or the HVBATT codes are linked to the PCS. Either way, service will get it fixed up for you.

 

[LDRHAWKE]

this is wild. at what point does it turn into a recall?

Good Article to read if you haven’t already. My PCS failed on my Beast and months later the wiring harness failed and went brick. The article says they should have both been replaced at the same time. My question is are they upgrading to what is installed in the 2026 or is this a quick makeshift fix.


ARTICLE:

Despite a growing number of confirmed cases, recognizable diagnostic codes, and reported service center backlogs, Tesla has yet to issue a formal NHTSA recall for the component. For many, the headache of having a looming threat in their vehicle, waiting to fail, means they may be hesitant to take road trips or plan travel without considering the possibility of being stranded on the side of the road.



The Symptoms

The Power Conversion System is a vital piece of the Cybertruck's power electronics. It acts as the gatekeeper for the vehicle's energy, integrating the On-Board Charger and the DC-DC converter into a single unit that manages all alternating-current power flowing into the battery while stepping down the high-voltage pack to power the truck's 48-volt low-voltage architecture.

There are several potential causes of PCS failure, which appear tied to failing MOSFETs or other internal components drifting out of spec under heavy electrical loads. Failures have been frequently reported at remarkably low mileage, often below 10,000 to 18,000 miles, and have occasionally happened repeatedly on the same vehicle after a full PCS replacement.



There are a few known symptoms that appear before full failure, which can help owners diagnose an issue before a full failure occurs:

• Sudden “AC Charging Unavailable” warnings on the primary DisplayPort
• AC charging speeds are throttled from 48A to 24A or lower before failing completely at home chargers
• PowerShare V2L and PowerShare V2H output errors
• Diagnostics codes in Service mode related to the PCS, including PCS2_a094, PCS2_a095, PCS2_a137, and those related to High Voltage DC overcurrent trip failures

In many cases, the truck can still be driven and accept DC fast charging at Superchargers. However, without the ability to AC charge at home, the vehicle's convenient daily use is effectively bricked until it undergoes major surgery.



Invasive Repairs and High Costs

Fixing a failed PCS is not a simple parts swap. Because the unit is buried deep within the vehicle's architecture, service technicians must remove the tonneau cover, the bed floor, and elements of the air suspension just to access it.



Under the primary Basic Vehicle Limited Warranty (4 years or 50,000 miles), Tesla covers replacement, often installing an updated hardware revision (Rev G) along with a new wiring harness.



However, for high-mileage owners whose trucks are already out of warranty, the costs have been staggering. Previously, an out-of-warranty PCS replacement cost between $5,000 and $7,200 for parts and labor. Tesla has recently lowered this cost to approximately $1,000 as a "goodwill" gesture, but owners are still footing the bill for what appears to be a systemic hardware defect.



Further compounding the frustration, Service Centers are currently dealing with severe parts shortages. Pickup dates for affected trucks have slipped multiple times, with owners reporting no firm lead times for the replacement units. According to one owner on social media, a Tesla service employee allegedly admittedthat the "first 75,000 Cybertrucks had defective PCS systems prone to failure."



The Terrestrial Armor Problem

The already invasive repair process becomes significantly more complex for vehicles equipped with the Terrestrial Armor retrofit or factory package. This heavy-duty underbody shield must be fully removed and carefully reinstalled to access the deeply buried power electronics.



According to service documentation, dealing with the Terrestrial Armor can increase the repair time to approximately eight hours of total labor. For owners outside their warranty window, this added complexity means Tesla may be charging a massive premium in pure labor hours just to access the failing component, adding significant financial sting to an already frustrating breakdown.



The Warranty Discrepancy

Adding insult to injury is how Tesla is handling long-term coverage for the vehicle. Tesla recently introduced a new 7-year/70,000-mile ZEV propulsion parts warranty for 2026+ model year Cybertrucks, which explicitly covers high-priced propulsion components like the PCS.



Early adopters who purchased 2024 and 2025 Foundation Series trucks are not provided this retroactive protection. For these older trucks, the PCS is covered solely under the basic vehicle warranty, which expires at just 50,000 miles.

Furthermore, unlike the Model S, Model 3, Model X, and Model Y, Tesla does not currently offer an Extended Service Agreement (ESA) subscription for the Cybertruck. Owners of early models are entirely exposed to repair costs once they cross the 50,000-mile threshold.



Where is the Recall?0

Despite the clear pattern of failure affecting dozens of confirmed vehicles, and reports that some service centers proactively replace the PCS when trucks come in for unrelated tire or trim service, there is no official NHTSA recall or proactive owner notification specifically addressing the PCS hardware defect.



For now, early Cybertruck owners are left hoping their PCS either fails safely within the initial 50,000-mile warranty window or survives long enough for Tesla to officially acknowledge the defect and issue a sweeping recall.

 

[rlac]

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[waltm]

Just to document, my VIN is 078747.

 

[Eka]

Question: If you had a Rev-G fail, did you have a previous failure?

I'm wondering if some PSC failures are damaging other parts.

 

[cyberHoward]

No. See attached.

I have concerns that it is not the PCS at all based on these codes. I guess we will see when the repair happens and I get the CT back.

I have the Powershare Gateway. I had some powershare errors as far back as November or December. I then had the HVBATT not charge & may not restart errors in late February. About a month later I had the PCS2 errors. I have successfully used powershare twice for over 24 hours in the past 60 days. The day my first PCS2 error came I charged my truck multiple times at home to prep for storms in the area.

Fortunately, I am still charging at 24 amps for now trying to limp to my May 4th appointment.

Did someone say they had revision G and there CT failed again and bricked? Also, that they did not change out the harness when replacing the PCS unit and that could potentially be the issue. Obviously, we all want to know if version G is going to work for them next 100k+ miles.

 

[BlueLightning]

So glad to wait, PCS the 1st 50k miles is hit or miss.

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