How are battery modules repaired in electric vehicles?

By repairing individual modules, avoiding costly replacements.

What design flaws are addressed in rebuilt Tesla drive units?

Coolant seal failures and bearing issues are rectified.

Using specialized tools like modified transmission jacks.

Battery replacements range from $10,000 to $20,000, while repairs are more cost-effective.

Steel bearings are prone to wear and failure, leading to noise and damage.

Repairing battery modules is a viable alternative to costly replacements, with only specific components needing attention, as highlighted by Alex at QC Charge.
Specialized tools and techniques are essential for servicing electric vehicles effectively, emphasizing the importance of precision and expertise in addressing unique components like drive units and batteries.

How are battery modules repaired in electric vehicles?
By repairing individual modules, avoiding costly replacements.
What design flaws are addressed in rebuilt Tesla drive units?
Coolant seal failures and bearing issues are rectified.
How are drive units safely removed from electric vehicles?
Using specialized tools like modified transmission jacks.
What is the cost difference between battery replacements and repairs in electric vehicles?
Battery replacements range from $10,000 to $20,000, while repairs are more cost-effective.
What are the common issues with bearings in electric vehicle drive units?
Steel bearings are prone to wear and failure, leading to noise and damage.

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Braden visits QC Charge in Vista, California to shed light on servicing electric vehicles.
Alex, a technician at QC Charge, explains that battery replacements are often unnecessary as modules can be repaired.
A Tesla Model S battery with a bad brick exemplifies repair possibilities, with only one module needing attention out of 16.
Contactors in earlier Tesla packs, like the Model S, can burn out but are easily replaceable.
Tesla typically opts for battery replacements rather than repairs, quoting prices ranging from $10,000 to $20,000.
QC Charge specializes in rebuilding Tesla drive units, addressing design flaws like coolant seal failures.
Drive units from cars like the Toyota RAV4 EV and Mercedes b-class electric are rebuilt with enhancements for improved reliability.
Bearings in drive units can cause issues, with steel bearings prone to wear and failure, leading to noise and damage.
RAV4 EV and Mercedes b-class cars, built under a partnership with Tesla, have unique powertrains and battery specifications.
Special tools, like custom-built motor stands, are essential for servicing electric vehicles due to limited availability in the market.

14:22

A modified transmission jack is used for the RAV4 EV and Mercedes B-Class Electric to safely remove the motor without causing damage, with a special plate for stability and support.
A lifting plate attaches to the motor for easy lifting using an engine crane or forklift, securing it with three bolts in factory fixture locations.
A tool is designed for safely removing inverters from motors to prevent damage to sensitive electronics, with a hooking mechanism to avoid contact with circuit boards.
A press is utilized to remove rust buildup in large drive units, preventing motor seizure by pushing out the rotor with wooden blocks to catch it.
A lathe is used for repairing rotors by turning down pitted or grooved surfaces, addressing issues with rotor sealing surfaces.