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Tesla Model S Drive Unit Replacement by the Numbers

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During my early days of researching the Tesla Model S, I had concerns about a number of things that were emerging in the press. Fires, Model S drive unit issues, and handling in the snow. Tesla quickly addressed the “firegate” issue by retrofitting the Model S with a titanium shield. My concerns around winter driving, in particular handling in the snow, also became a non-issue after watching several winter driving videos put together by Bjørn Nyland.

Within no time, I became a new Model S owner and quickly learned that driving in the winter could actually be quite fun with a good set of winter tires. Tesla later introduced the all-wheel drive “D” models putting to rest any remaining doubt that the Model S could be the best and safest handling car in the world.

But one question still remains for me, Has Tesla dealt with the Drive Unit issues?

Model S Drive Unit Replacement by the Numbers

There is a group of Model S owners across the forums, but also validated by major publications such as Edmunds, that have had one or more drive unit replacements.

Early reports of drive unit issues ranged from total failures that left the Model S inoperable, to more recent complaints of clunking and milling noises. Elon has said in the past that many of these pre-emptive drive unit replacements were unnecessary and a simple $0.50 shim was all that was really needed, yet Tesla Service centers have been proactively replacing drive units.

The following polls from TMC show that a majority of Model S owners have had their drive units replaced.

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Drive Unit Poll

While the poll only represents a small sample of Model S owners, one might draw significance in the numbers as the density circles around owners needing a drive unit replacement at relatively low mileage, and without any harsh driving prior to failure.

The polls also give insight to the motive behind each drive unit replacement.

Non replaced DUs

DU replacements by build date

 

Though it appears the issues mainly center around earlier versions of the Model S, there’s been reports of newer Model S with Autopilot hardware hearing milling noises coming from the drive unit. One viewer described the sound as “sawing wood”.

 

 

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Tesla’s Response to Drive Unit Issues

In typical Tesla fashion, the company acted fast to address the issues, and curb concerns by offering an unlimited mile/8 year warranty on the drive unit. I think this was a great response by Tesla which put to rest any concerns about the quality and long term durability of their drive units.

Elon is now talking about building a power train that will last a million miles and I believe Tesla continues to put significant energy into improving the drive units. Tesla continues to honor the warranty and is proactively replacing drive units that show early signs of problems.

Tesla-Drive-Unit

 

My Experience

After 12 months of Model S ownership and 30k miles drive, I started hearing a humming noise from the rear of my Model S during highway cruising. The noise was unusual as I had gotten used to hearing only the noise of the tires and wind, but there was a new noise only noticeable when cruising or decelerating with regeneration at 65 MPH and over. The noise continued to become more audible over the next few months, but I learned to live with it and did not contact Tesla. My personal rule of thumb on noise related issues is to wait for passengers to comment on it first. It’s my self crazy check.

Two months after the original drive unit humming noises began, a higher pitched milling type noise started occuring when traveling at speeds of 20 MPH or less. The sound varied depending on how much power was being used. That’s when I reached out to Tesla.

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Drive unit details

Tesla service record

 

Tesla service had me come in for a test drive which they can do on demand without you needing to wait. We drove about a block before the Tesla service technician said the drive unit needed to be replaced.

The explanation was that tolerances inside the drive unit have led to metal particles getting into the fluid around the drive unit, and as the concentration of particles increased, it caused the noise from the drive unit to become louder when under load. The new drive units evidently have better tolerances and are less prone to having metal particles being shaved off.

At that time, Tesla service has been very backed up here in Massachusetts so my appointment for the drive unit replacement was scheduled six weeks out. I put on another 4,000 miles during that wait time, with an increasingly louder drive unit, before it was finally replaced.

When Tesla replaces a drive unit, they replace both the drive unit and inverter as you can see from a copy of the parts list. The last letter in the drive unit part number (“M” in my case) seems to indicate the generation of the drive unit. The later the letter the better, with the “Q”s seeming to have the best longevity according to the forums.

I’m happy to say that I’ve logged 8,000 miles of happy and noise-free driving after my drive unit replacement. The replacement was done recently so my guess is that I have a newer unit, and thus hope this will be my only replacement.

Thankfully for all of us, Tesla has a first class warranty and level of service. While it goes without saying that inconveniences such as this may happen, rest assured that Tesla has you covered and will always strive to make things right.

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"Rob's passion is technology and gadgets. An engineer by profession and an executive and founder at several high tech startups Rob has a unique view on technology and some strong opinions. When he's not writing about Tesla

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Starlink Mini 2 arrives with one feature for true off-grid connectivity

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Credit: SpaceX

SpaceX officially launched the Starlink Mini 2 on November 10, delivering the first portable Starlink terminal designed around independent power.

Invitation-only preorders for select U.S. customers are priced at $999 plus tax, a figure that includes a full year of Roam Unlimited service valued at roughly $2,100. A refundable $100 deposit reserves the kit, with the balance due at shipment, expected to begin in mid-December. Broader availability is listed as coming soon.

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The headline feature is the quick-swap 71 Wh battery. Clipped to the rear of the dish without tools, it delivers up to 4.5 hours of connectivity on a single charge.

The 490-gram pack includes its own USB-C port and LED indicators, so users can charge a spare separately and swap it in seconds while staying online. Starlink notes that the terminal can continue operating while the battery charges or run directly from a 60 W USB-C source. The retail box includes one battery, a 60 W USB-C charger, and a 3-meter cable.

Beyond power, the Mini 2 is thinner at 23.1 mm (versus 38.5 mm on the original Mini) while measuring 263 × 314 mm. With the battery and kickstand attached it weighs 1.6 kg.

Built-in Wi-Fi 6 expands coverage to up to 1,800 square feet, an IP67 rating protects against dust and water, and a standard 1/4-20 tripod thread plus physical power button round out the design. Field of view remains 110 degrees, and the unit retains support for mobile use.

For travelers, campers, and remote workers, the swappable battery removes the longstanding requirement for an external power bank or vehicle outlet that defined the first Mini. Spare packs sold separately further extend runtime, turning the compact terminal into a more self-contained solution.

While the bundled $999 invitation price sits well above the original Mini’s current $149 starting point, the included year of service and genuine untethered operation mark a clear step forward in portable satellite internet.

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SpaceX’s $24B Starbase supercomputer plan slipped past a key roadblock

SpaceX wants a Starbase tax break for a $24 billion gas plant and supercomputer campus.

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Concept rendering of SpaceX President Gwynne Shotwell overlooks the company’s Hawthorne, California headquarters as an American flag flies over the campus at sunset.

SpaceX is asking its own company town for a tax break on a $24 billion natural gas power plant and supercomputing facility at Starbase, Texas, and the land it picked sits just outside the reach of a data center moratorium that took effect in neighboring Brownsville last week.

A City of Starbase public hearing notice says SpaceX “proposes to construct, own, and operate a gas-fired power plant and super-compute facility” on roughly 444 acres between Boca Chica Boulevard and the Port of Brownsville. The $24 billion figure covers only the initial phases, and the notice leaves room for future expansions. The Starbase City Commission will consider a property tax abatement and a related economic development agreement at a 7 p.m. hearing on December 9. The notice does not disclose the size or length of the abatement, or how much computing capacity the site would hold.

The location has a history. Over the summer, SpaceX asked Brownsville to remove the tract from its city limits and offered $220 million for water and wastewater projects in return. Brownsville approved the move in August, and Starbase later annexed the land. Brownsville’s own 90-day pause on data center applications took effect last week, and had the tract stayed inside the city, the project likely would have needed a different home.

The power side is already in front of state regulators. SpaceX has applied to the Texas Commission on Environmental Quality for air permits covering 35 mobile gas turbines producing roughly 750 megawatts, according to Politico, which also noted that two of the three Starbase commissioners voting on the incentives are SpaceX executives.

Building its own plant lets SpaceX skip the Texas grid. Gov. Greg Abbott paused new data center grid connections in August pending an audit, but a facility that generates its own electricity does not need one. The air permit still has to clear the TCEQ, where Abbott also ordered a halt on data center permits.

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The bigger test arrives in January. Governor-elect Gina Hinojosa, who unseated Abbott last week, has said she will block data center approvals until the legislature passes new protections, and she has already asked state officials to hold off on any sale of Boca Chica State Park to SpaceX until she is sworn in. Tesla and SpaceX shares both fell the day after the election, and Musk’s first reaction on X was “Data centers in space looking pretty appealing right now.”

That line points to Starmind, SpaceX’s orbital compute constellation. Musk has said terrestrial compute will be “peanuts compared to orbital compute” and expects monthly orbital deployments to pass ground deployments around the end of 2028, as Teslarati reported. Until then, SpaceX still needs gigawatts on the ground. It ended the third quarter with 1.7 GW of nameplate compute, is targeting 2.5 to 3 GW by the end of this year and wants at least 10 GW more in 2027. Its existing Colossus sites around Memphis already run on gas turbines and face a lawsuit from residents over emissions.

Local reaction is split. The South Texas Environmental Justice Network has announced a protest, citing air quality, water use and energy bills, while some Brownsville residents told the Tribune they welcome the jobs. SpaceX did not respond to the Tribune’s questions about the project.

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Tesla extends Cybertruck production as Musk concedes ‘sentimentality’

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Credit: diagnosticdennis/Instagram and @smile__no via Tesla Owners of Santa Clarita Valley/X

Tesla CEO Elon Musk announced that the company will extend Cybertruck production slightly to handle its extensive order backlog.

On Wednesday, Musk announced that “In order to work through more of the Cybertruck order backlog, production will be extended through the end of summer 2027.”

Tesla has already attempted to simplify its last months of production for the Cybertruck by eliminating several trim levels and only offering the Cyberbeast, the most expensive trim that starts at $109,990. The other two trim levels, the Cybertruck All-Wheel-Drive and Premium All-Wheel-Drive have both been discontinued.

There has been plenty of backlash against Tesla’s decision to ax the Cybertruck, but the company’s forecast prioritizes Cybercab and autonomy. Factory space at Gigafactory Texas that is not necessary is now being set aside for the Cybercab as the company truly embraces its “transportation-as-a-service” model.

There is still a slim chance the Cybertruck survives. Last evening, Tesla upfitter Unplugged Performance offered to take the Cybertruck line off of Tesla’s hands and continue building it, along with a CyberSUV.

Nevertheless, Tesla seems to be ending the Cybertruck on its terms after what will be a three-and-a-half-year run. It still does not really feel quite real; I think many of us thought the Cybertruck would be around for years to come.

Musk added more detail, stating that while it was not the smartest move, “there must be some room in this world for sentimentality or what’s the point?”

Other EV pickups on the market have experienced a similar fate.

The Ford F-150 Lightning was axed by the Detroit company due to the continued losses the company took from sales. That truck was never profitable, and Ford is still taking a quarterly loss in its EV side. However, things are moving along as it has plans for a mass market EV pickup, which will likely gather some substantial demand if Ford can get it just right.

Perhaps another extension or even a total change of heart might come. Only Musk knows.

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