PCS Failure - Can’t charge at all

[seussiii]

So are most of you able to charge at a slower rate? Any of you ending up unable to charge? This would really suck while 500+ miles away from home on a road trip.

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[jf64k]

Add me to the list. Limited to 24amps. Service menu errors. 15k miles

Were you charging at 48 amps typically?

I ask because I’ve got FS AWD May, 2024 w/30k. I charge almost exclusively at home at 40 amps, not 48.

 

[Fausto]

Were you charging at 48 amps typically?

I ask because I’ve got FS AWD May, 2024 w/30k. I charge almost exclusively at home at 40 amps, not 48.

Yeah, normally 48amps 11kw on a Tesla wall charger.

Service is booked for two weeks away. Nearest service center apparently can't perform the repair. So I have two weeks to see if this becomes a fatal failure and then maybe a 125mile journey to the nearest SC that can fix it. Lame.

 

[kpanda17]

Yeah, normally 48amps 11kw on a Tesla wall charger.

Service is booked for two weeks away. Nearest service center apparently can't perform the repair. So I have two weeks to see if this becomes a fatal failure and then maybe a 125mile journey to the nearest SC that can fix it. Lame.

its a slow death

 

[txtravwill]

I always charged at 40amps, down to 24amps now. Service appointment setup for around March 6th I think so hopefully last until then ;-)

 

[mongo]

Kind of a depressing thread. Fun for keyboard experts but for the regular informed consumer it sucks. My take is that this whole mess had a very predictable outcome. When a product is built and supply chain agreements set based upon a run rate of 250,000-500,000/units yearly and the actual numbers 2 plus years later are short by 90% that's got to be a BIG problem.

I say this as someone who just ordered a 2026 DM and I had fallen for the very interesting engineering story behind the Cybertruck rather than the production reality. At the current build rates Tesla has little to no influence with the supply chain vendors to revise/replace components that were either poorly engineered or manufactured or both.

It could be said that the PCS failure rate is indicative of a logical but radical move to a 48V architecture in a 12V world. It has been said 48V is the future but that future depends upon wide adoption by supply chain vendors. Tesla discovered that with many 12V components still in play and due to vastly misjudged run rates, the subsequent supply chain issues could and should have been predicted.

With Cybertruck demand being +/- 10% of original projections, the entire picture of the suppliers seeing huge quantity drops in component orders would inevitably lead to quality drops as well. Many components for SBW and RWS were outsourced and imagine how those contractors look at this huge reduction in quantity of orders. Of course this issue applies to virtually all of the non-Tesla made components and even Tesla is re-purposing Cybertruck lines for other products.

The Model 3 and especially the Model Y sales numbers made everyone from Tesla to their suppliers happy. The grossly mis-judged sales numbers for the Cybertruck make me wonder how it could possibly continue as a viable product. It also gives me pause as to the wisdom of my CT order and my long term plan of ownership of that vehicle.

If my logic is not sound and/or my conclusions flawed, I'd love to hear why I should stay on the path to Cybertruck ownership. Right now, I risk only a $250 order fee.

The switch to 48V is a separate issue from the PCS DCAC failures. The DCDC section seems to be reliable.
One might make a link to the 800V pack though, or the bidirectional operation. Those are relevant step changes from previous architectures along with topology change. Maybe there is a marginal portion of the design (hardware or software). There was an issue with supplier quality on the drive unit inverter FETs, could be something similar.

Reduced sales volume wouldn't back propagate into poor module quality, especially on early production. Supplier agreements don't allow unapproved module changes and revalidation costs can make it more advantageous not to push for a part cost reduction given the limited quantity to recoup the NRE.

 

[Hanzo]

yes affects AC charging also, typically non of us hawk over the AC charging rate, making sure we get 48 amps
you notice it more with DC charging as we all want the highest speed when mobile
regardless, take screen shots of the AC reduced rate
push them politely/hard for the PCS replacement
good luck

From service:

Confirmed PCS failed internally. Replaced PCS and installed harness ferrite. Vacuumed coolant system and filled to max. Ran coolant air purges. Vehicle is now operating as intended.

And I never got a PCS error. Just the 48volt system error which bricked the truck. Worrisome for early CT owners past 50k warranty. Should be a recall or extend the warranty for early owners.

 

[NXTruck]

From service:

Confirmed PCS failed internally. Replaced PCS and installed harness ferrite. Vacuumed coolant system and filled to max. Ran coolant air purges. Vehicle is now operating as intended.

And I never got a PCS error. Just the 48volt system error which bricked the truck. Worrisome for early CT owners past 50k warranty. Should be a recall or extend the warranty for early owners.

I’m taking mine in tomorrow at 6:45 AM. Did they finish yours in the same day? The estimate completion is 5 PM.

 

[jf64k]

Add me to the list, haha!!

FS AWD, 05/24 delivery, 11xxx, 35k

Just plugged in the wall connector and it went to 24A/24A (normally I’m at 40A/40A). Haven’t checked Service Mode yet, but we all know what’s up, haha!!

Submitted a service ticket. Added non-auto close tonneau and loose rear PWS speaker to the service request, too.

ETA: ‘PCS Blues’ confirmed, haha!!

 

[NXTruck]

The low power mode really works well. I lost only a few % over 8 days while waiting for service. They got it done in 30 hours and back to 48a.

 

[Jhodgesatmb]

I just had this happen to me. My service

Hi Dustin,
So I just dropped off my CT at Buena Park Tesla for the PSC replacement today. My CT has 56,000 miles. Just like you, my advisor first sounded like it would be covered under warranty but then I got a quote for about $3700. After letting them know how upset and disappointed I was, the service manager did give me a discount. But I think all the CT owners need to take their trucks in and have it replaced even if its not broken yet. Because it will. It's just a matter of will you be lucky enough for the part to break while its under warranty or not. And if the advisor says that he can't replace it, I would ask him to put it in writing that you don't have to pay to replace it if it goes out later. This is not a wear and tear part. It should last the lifetime of the car. The fact that Tesla knows about this problem but won't make it right with their customers is really disappointing.
This should be a recall issue. That's why I urge everyone to go to your dealers and demand that you get a new PCS module. I think if enough customers go in with the same issue, the manufacturer has to post a recall.
Also, some of you asked if there were signs of this before... my CT was charging at 24 amps instead of 48 for a couple of days before it stopped charging all together. So, yeah, take your car in and request that the PCS be replaced. For sure it will not go easy. Be prepared to put up an argument. Our only chance in winning this thing is strength in numbers, unity, and social media.

I just got these alerts today. I am just over 30,000 miles. I do not recall what the warranty is but if this is happening (or will) to every CT owner then it will eventually be a recall item. I wonder if the NHTSA has been informed. Since I haven't taken mine in yet I do not know if I can submit a complaint to the NHTSA. Ok, I just did submit a complaint to the NHTSA:

https://www.nhtsa.gov/report-a-safety-problem#/vehicle/form-submit

 

[Jhodgesatmb]

let’s get orgabized
Is there a form or email?

https://www.nhtsa.gov/report-a-safety-problem#/vehicle/form-submit

 

[Jhodgesatmb]

FYI, NHTSA cares about safety and regulation compliance based issues. Charging (or lack thereof) isn't in that scope.
Better luck might be had via your state's attorney general or the FTC https://www.usa.gov/car-complaints.
However, unless you specifically opted out, the purchase agreement included an arbitration clause which may supersede those routes (I'm no lawyer).

If you are out on the road and you cannot charge your car ... you are saying that isn't a safety issue? I just submitted it to the NHTSA as a safety issue and that is how I feel about it.

 

[mongo]

If you are out on the road and you cannot charge your car ... you are saying that isn't a safety issue? I just submitted it to the NHTSA as a safety issue and that is how I feel about it.

I am saying it is not an issue The National Highway Traffic Safety Administration deals with. The failure mode is akin to running out of gas with a working fuel gauge due to your fuel door not opening versus having your fuel pump suddenly fail while doing 70 on the freeway.

What is a safety-related defect?
Generally, a safety defect is a problem that poses a risk to motor vehicle safety, and may exist in a group of vehicles or equipment of the same design and/or manufacturer. An example of a safety-related defect is a steering component that breaks, causing a driver to lose control. However, paint quality or cosmetic blemishes are not considered safety-related defects, because they do not pose a risk to motor vehicle safety.

The other two agencies I listed may care more.

 

[Jhodgesatmb]

I am saying it is not an issue The National Highway Traffic Safety Administration deals with. The failure mode is akin to running out of gas with a working fuel gauge due to your fuel door not opening versus having your fuel pump suddenly fail while doing 70 on the freeway.



The other two agencies I listed may care more.

I guess I don't see a difference between you having your fuel pump fail at 70 and your car stopping because you ran out of gas in the middle of nowhere. You're still screwed and that is a safety issue. It may be true that the NHTSA won't care but I submitted a complaint anyway.

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