NEW PCS (Power Conversion System) Failure & Replacement News

[EWELON]

interesting pcs saga from one of the first available and longest used CTs

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[funnbobby]

interesting pcs saga from one of the first available and longest used CTs

Wow. Thanks for sharing.

 

[nevetsyad]

Proactive action would be for Tesla to acknowledge the failues, recall the defective part, not wait until their customers are stranded 100’s miles from a Tesla SC. I don’t appreciate having to worry everytime I plan a tripm that I will stranded and left to deal with the problem.
I tried to be proactive by scheduling PSC replacement before taking long vacation trip, but was told “can’t schedule, have to wait for part failure”. SC gave me their direct phone number, said “call me directly when (not IF) truck fails to charge,, will see what can do at that time”. (I guess you can call that “proactive”!!! Yes, I am also a Tesla investor plus owner of two Tesla vehicles, I don’t believe this is the way any company should treat their loyal customers.

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!

 

[Sjohnson20]

Main problem is only Tesla can fix it. If I was driving a gas car and the gas tank fell off a shop could fix it for me. Not being able to fill your car is a pretty major problem.

 

[nevetsyad]

Main problem is only Tesla can fix it. If I was driving a gas car and the gas tank fell off a shop could fix it for me. Not being able to fill your car is a pretty major problem.

That's not a Tesla problem, that's an EV problem. My GM EV had issues and I was told to take it to their EV specialist in a neighboring state. Kind of insane.

But there are more and more EV repair shops opening up. Plenty of stories of Tesla saying someone needs a 14 grand battery pack, and an EV repair shop replaces a few cells for $400 or something, and it's good as new. They're spreading. We're still in the early times.

 

[EWELON]

That's not a Tesla problem, that's an EV problem. My GM EV had issues and I was told to take it to their EV specialist in a neighboring state. Kind of insane.

But there are more and more EV repair shops opening up. Plenty of stories of Tesla saying someone needs a 14 grand battery pack, and an EV repair shop replaces a few cells for $400 or something, and it's good as new. They're spreading. We're still in the early times.

is that possible for our battery though? i thought that our skateboard was bascially a solid mass of cells and glue.

 

[Jhodgesatmb]

is that possible for our battery though? i thought that our skateboard was bascially a solid mass of cells and glue.

You are correct. Sandy Munro did a tear down of a Cybertruck battery and there is no way to repair a cell. The battery warranty should take us out several years and then new chemistries might make a swap a better idea anyway.

 

[JCERRN]

Main problem is only Tesla can fix it. If I was driving a gas car and the gas tank fell off a shop could fix it for me. Not being able to fill your car is a pretty major problem.

Well, to be clear, with the right tools, parts, and facility, anyone can fix it… its just prohibitively expensive and time consuming for anyone but a shop to replace it. One of the best things about these vehicles are that they are basically built like legos. As long as you have the right resources they are pretty straight forward to repair. Tesla sells most parts direct to consumer.

 

[Outdoors]

That's not a Tesla problem, that's an EV problem. My GM EV had issues and I was told to take it to their EV specialist in a neighboring state. Kind of insane.

But there are more and more EV repair shops opening up. Plenty of stories of Tesla saying someone needs a 14 grand battery pack, and an EV repair shop replaces a few cells for $400 or something, and it's good as new. They're spreading. We're still in the early times.

That whole cell repair stuff has been debunked on other forum. Short term fix that doesn't have long term good outcomes.

 

[TTRUCK]

As all current badge owners of failed PCS know this part failure has caught on like wildfire.. I just picked up my CT after getting the new revised part installed "G" and my SC has told me they are swamped with PCS failures.

I proceeded to inquire about cost to replace the part if I was without warranty and they stated that the cost to replace was around $4,000 but due to high failure rate the new cost to replace is around $1000.

This news might alleviate some stress for those without warranty.

This comes from Naperville Service Center, here near Chicago..

For what it is worth this is what Gemini has to say as to who is most at risk of a failure.

Tesla’s Revision G (Rev G) Power Conversion System (PCS) units began appearing in Cybertruck production around late April 2024 to early May 2024.

This revision was introduced to address early reliability issues with the 48V architecture, specifically involving the DC-DC converters and AC charging failures.

Key Production Timeline

• Initial Launch (Late 2023 – March 2024): Most trucks were equipped with Revision E or Revision F units. These early versions were the primary focus of owner reports regarding "AC Charging Unavailable" errors and 48V system shutdowns.
• Introduction of Revision G (April/May 2024): Technical service data and owner teardowns (such as those documented by Munro & Associates and community forums) noted the shift to Revision G parts. Owners with VINs roughly above the 10,000–12,000 range (manufactured in May 2024 and later) typically find Rev G units pre-installed.
• July 30, 2024 Cutoff: This is a critical date in Tesla's hardware history for the truck. While Revision G was already in the mix, units built after this date include the updated MOSFET components that solved the drive inverter failures leading to the late-2024 physical recall.
  
  

How to Verify Your Revision
If you want to check which version is in your Cyberbeast, you can often see the part label without significant disassembly:

1. Open the Powered Frunk.
2. Remove the Ancillary Bay cover (the plastic trim piece near the windshield/wiper area).
   
   
   
3. Locate the PCS unit (a large aluminum housing with orange high-voltage cables and blue coolant lines).
4. Check the white sticker for the part number. It will typically look like 1802305-00-G or similar, where the "G" denotes the revision.

Note: If your truck was manufactured before May 2024 but has had a PCS replacement at a Service Center due to a charging failure, it is highly likely you were upgraded to Revision G (or newer, such as Revision H/J) as part of the repair.

 

[Black306]

For what it is worth this is what Gemini has to say as to who is most at risk of a failure.

Tesla’s Revision G (Rev G) Power Conversion System (PCS) units began appearing in Cybertruck production around late April 2024 to early May 2024.

This revision was introduced to address early reliability issues with the 48V architecture, specifically involving the DC-DC converters and AC charging failures.

Key Production Timeline

• Initial Launch (Late 2023 – March 2024): Most trucks were equipped with Revision E or Revision F units. These early versions were the primary focus of owner reports regarding "AC Charging Unavailable" errors and 48V system shutdowns.
• Introduction of Revision G (April/May 2024): Technical service data and owner teardowns (such as those documented by Munro & Associates and community forums) noted the shift to Revision G parts. Owners with VINs roughly above the 10,000–12,000 range (manufactured in May 2024 and later) typically find Rev G units pre-installed.
• July 30, 2024 Cutoff: This is a critical date in Tesla's hardware history for the truck. While Revision G was already in the mix, units built after this date include the updated MOSFET components that solved the drive inverter failures leading to the late-2024 physical recall.
  

How to Verify Your Revision
If you want to check which version is in your Cyberbeast, you can often see the part label without significant disassembly:

1. Open the Powered Frunk.
2. Remove the Ancillary Bay cover (the plastic trim piece near the windshield/wiper area).
   
   
   
3. Locate the PCS unit (a large aluminum housing with orange high-voltage cables and blue coolant lines).
4. Check the white sticker for the part number. It will typically look like 1802305-00-G or similar, where the "G" denotes the revision.

Not a fan of LLMs ATM. Tried using several to find a part for another car. They are very often confidently wrong. In this case, PCS is under the bed, not under the frunk.

https://service.tesla.com/docs/Cybe...UID-8F133FA6-44FC-4D62-9BD3-03C92951B916.html

 

[Leifmb]

As all current badge owners of failed PCS know this part failure has caught on like wildfire.. I just picked up my CT after getting the new revised part installed "G" and my SC has told me they are swamped with PCS failures.

I proceeded to inquire about cost to replace the part if I was without warranty and they stated that the cost to replace was around $4,000 but due to high failure rate the new cost to replace is around $1000.

This news might alleviate some stress for those without warranty.

This comes from Naperville Service Center, here near Chicago..

I had my PCS replaced in Mar 2026 (at 10,629 miles) and the part was: Power Conversion System - 48AMP 1777777-T2-G. I'm assuming that last "G" means I got the updated version? There was also a "Ferrite Round Cable for Harness 2134590-00-A replaced. My Cyberbeast was built in JAN 2025. VIn 61K

 

[kpanda17]

I had my PCS replaced in Mar 2026 (at 10,629 miles) and the part was: Power Conversion System - 48AMP 1777777-T2-G. I'm assuming that last "G" means I got the updated version? There was also a "Ferrite Round Cable for Harness 2134590-00-A replaced. My Cyberbeast was built in JAN 2025. VIn 61K

standard set of parts
Yes, G seems to be the keeper revision

 

[Leifmb]

standard set of parts
Yes, G seems to be the keeper revision

I would guess that my truck originally came with the “G” version as it was made in Jan 2025! That’s the concerning point! 🫣

 

[mongo]

I would guess that my truck originally came with the “G” version as it was made in Jan 2025! That’s the concerning point! 🫣

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

Interesting. Mine was replaced with

48AMP(1777777-12-E)

back in April 2025. Maybe they updated the part? Wonder if E revisions were failing too, necessitating a subsequent F, then now G? Who knows…

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