The 2016 Model S is fundamentally solid but plagued by early-generation drive unit issues, high-voltage component failures, and Tesla's infamous build quality quirks. Expect expensive repairs once warranty expires, and factor in that independent diagnosis can be challenging without Tesla tooling.
Drive Unit (Rear Motor) Failure or Noise
Common · high severity
Typical onset: 60,000-100,000 mi
Symptoms: whining, humming, or clunking from rear axle, drivetrain vibration at highway speed, milling noise on acceleration, occasional total loss of propulsion
Fix: Drive unit replacement or rebuild. Tesla warranty covered many, but out-of-warranty units run 8-12 hours labor plus remanufactured drive unit. Independent shops can swap units but sourcing and programming requires Tesla cooperation or third-party workarounds.
Estimated cost: $5,000-9,000
High Voltage Battery Degradation and Module Failures
Occasional · high severity
Typical onset: 80,000-120,000 mi
Symptoms: rapid range loss beyond normal degradation (>20% capacity drop), brick warnings or BMS faults, car won't charge past certain percentage, reduced power output and limp mode
Fix: Full pack replacement is $12k-22k depending on capacity. Some shops can replace individual modules (16-module packs) for $2k-4k if only one or two are bad, but diagnostics require Tesla scan tools or third-party equivalents. Labor is 10-14 hours for full pack, 6-8 for module replacement.
Estimated cost: $3,000-22,000
Main Battery Contactors Sticking or Failing
Occasional · high severity
Symptoms: car won't wake up or start, clicking from under rear seat area, error messages about contactor open/close failure, total loss of drive with dash warnings
Fix: Contactor replacement inside HV battery assembly. Requires disconnecting HV system, removing pack access covers. 4-6 hours labor. Parts are $800-1,500 depending on whether you get OEM or aftermarket.
Estimated cost: $1,500-3,000
Door Handle Mechanisms Freezing or Failing to Present
Common · low severity
Symptoms: handles don't extend when approaching car, handles stuck retracted or partially extended, grinding noise from door when unlocking, intermittent function in cold weather
Fix: Door handle actuator replacement. Each handle is 1.5-2 hours labor (door panel removal, careful cable routing). Revised Gen 2 handles are more reliable. Most owners end up replacing multiple handles over ownership.
Estimated cost: $500-800 per handle
MCU (Media Control Unit) eMMC Flash Memory Failure
Common · medium severity
Typical onset: 70,000-100,000 mi
Symptoms: yellow border around touchscreen, extremely slow screen response or black screen, navigation and backup camera not working, continuous reboot loops
Fix: MCU board repair (eMMC chip replacement) or full MCU upgrade to newer hardware. Board-level repair by specialists runs $500-700. Tesla's MCU2 upgrade is $1,500-2,500 installed and solves the issue permanently. DIY chip replacement possible but requires microsoldering skills. 2-3 hours labor for swap.
Estimated cost: $500-2,500
12V Battery Failures Causing Total System Lockout
Occasional · medium severity
Symptoms: car completely dead, won't unlock or respond, repeated warnings about 12V battery needing service, random module faults and warning lights, frunk won't open electrically
Fix: Replace 12V lead-acid battery. Unlike traditional cars, the DC-DC converter charges this from HV pack, but early Model S units had weak charging logic. Battery is in frunk area, 0.5-1 hour labor. Tesla-specific battery preferred but standard group-size AGM works. Some owners proactively replace every 3-4 years.
Estimated cost: $200-400
Suspension Air Compressor and Valve Block Leaks (Air Suspension Models)
Occasional · medium severity
Typical onset: 60,000-90,000 mi
Symptoms: suspension compressor running constantly, car sagging overnight or sitting lower on one corner, suspension fault warnings, rough ride or inability to raise suspension
Fix: Compressor or valve block replacement, sometimes air spring replacement if leak is at bag. Compressor is 2-3 hours, valve block is 3-4 hours. Air springs are $400-600 each plus 2 hours labor per corner. Diagnosis requires leak detection (soapy water method or ultrasonic).
Estimated cost: $1,200-3,500
Owner tips
Keep the 12V battery fresh—replace every 3-4 years even if it seems fine; most bizarre faults trace back to weak 12V.
Drive unit fluid should be changed every 12,500 miles per early service bulletins despite Tesla later saying 'lifetime fill.' Helps extend drive unit life.
Budget $2,000-3,000/year for out-of-warranty repairs once past 100k miles; HV component failures are expensive and not DIY-friendly.
Get a pre-purchase inspection with Tesla-specific scan tool (not generic OBD2) to check battery health, drive unit condition, and logged faults.
Buy only with clear service history and recent drive unit replacement, or factor $5k-10k repair cushion into your budget—capable luxury EV but expensive to maintain post-warranty.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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Tesla, Inc. (Tesla) is recalling certain 2012-2024 Model S, 2015-2024 Model X, 2017-2023 Model 3, and 2020-2023 Model Y vehicles. In the event of an unbelted driver, the seat belt warning light and audible chime may not activate as intended. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
Consequence: A seat belt warning system that fails to alert occupants of an unbelted seat belt can increase the risk of injury during a crash.
Remedy: Tesla will release an over-the-air (OTA) software update. Owner notification letters were mailed July 26, 2024. Owners may contact Tesla customer service at 1-877-798-3752. Tesla's number for this recall is SB-24-00-008.
Tesla, Inc. (Tesla) is recalling certain 2012-2023 Model S, 2016-2024 Model X, 2017-2023 Model 3, 2019-2024 Model Y, and 2024 Cybertruck vehicles. An incorrect font size is displayed on the instrument panel for the Brake, Park, and Antilock Brake System (ABS) warning lights. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 105, "Hydraulic and Electric Brake Systems" and 135, "Light Vehicle Brake Systems."
Consequence: Warning lights with a smaller font size can make critical safety information on the instrument panel difficult to read, increasing the risk of a crash.
Remedy: Tesla began releasing an over-the-air (OTA) software update, free of charge. Owners may contact Tesla customer service at 1-877-798-3752. Tesla's number for this recall is SB-24-00-003.
Tesla, Inc. (Tesla) is recalling 2012-2023 Model S, 2016-2023 Model X, 2017-2023 Model 3, and 2020-2023 Model Y vehicles equipped with all versions of Autosteer leading up to the version(s) that contains the recall remedy. In certain circumstances when Autosteer is engaged, the prominence and scope of the feature's controls may not be sufficient to prevent driver misuse of the SAE Level 2 advanced driver-assistance feature.
Consequence: In certain circumstances when Autosteer is engaged, and the driver does not maintain responsibility for vehicle operation and is unprepared to intervene as necessary or fails to recognize when Autosteer is canceled or not engaged, there may be an increased risk of a crash.
Remedy: Tesla will release an over-the-air (OTA) software update, free of charge. Owner notification letters were mailed February 10, 2024. Owners may contact Tesla customer service at 1-877-798-3752. Tesla's number for this recall is SB-23-00-008.
STEERING:AUTOMATED/ADAPTIVE STEERING · 23V085000
2023-02-15 · EA22002
Tesla, Inc. (Tesla) is recalling certain 2016-2023 Model S, Model X, 2017-2023 Model 3, and 2020-2023 Model Y vehicles equipped with Full Self-Driving Beta (FSD Beta) software or pending installation. The FSD Beta system may allow the vehicle to act unsafe around intersections, such as traveling straight through an intersection while in a turn-only lane, entering a stop sign-controlled intersection without coming to a complete stop, or proceeding into an intersection during a steady yellow traffic signal without due caution. In addition, the system may respond insufficiently to changes in posted speed limits or not adequately account for the driver's adjustment of the vehicle's speed to exceed posted speed limits.
Consequence: FSD Beta software that allows a vehicle to exceed speed limits or travel through intersections in an unlawful or unpredictable manner increases the risk of a crash.
Remedy: Tesla will release an over-the-air (OTA) software update, free of charge. Owner notification letters were mailed April 15, 2023. Owners may contact Tesla customer service at 1-877-798-3752. Tesla's number for this recall is SB-23-00-001.
Tesla, Inc. (Tesla) is recalling certain 2016-2022 Model S and Model X, 2017-2022 Model 3, and 2020-2022 Model Y vehicles. The "rolling stop" functionality available as part of the Full Self-Driving (Beta) software may allow the vehicle to travel through an all-way stop intersection without first coming to a stop.
Consequence: Failing to stop at a stop sign can increase the risk of a crash.
Remedy: Tesla will perform an over-the-air (OTA) software update that disables the "rolling stop" functionality, free of charge. Owner notification letters were mailed March 28, 2022. Owners may contact Tesla customer service at 1-877-798-3752. Tesla's number for this recall is SB-22-00-001.
LATCHES/LOCKS/LINKAGES:HOOD:LATCH · 21V00B000
2021-12-21
Tesla, Inc. (Tesla) is recalling certain 2014-2021 Model S vehicles. The front trunk latch assembly may be misaligned, preventing the secondary hood latch from engaging. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 113, "Hood Latch System."
Consequence: If the primary latch is inadvertently released and the secondary latch is not engaged, the hood could open unexpectedly, obstructing the driver's view and increasing the risk of a crash.
Remedy: Tesla Service will inspect and reposition the latch assembly as necessary, free of charge. Owner notification letters were mailed February 18, 2022. Owners may contact Tesla customer service at 1-877-798-3752. Tesla's number for this recall is SB-21-11-003.
BACK OVER PREVENTION:SOFTWARE · 21V035000
2021-01-29 · EA20003
Tesla, Inc. (Tesla) is recalling certain 2012-2018 Tesla Model S and 2016-2018 Model X vehicles with a center display equipped with a NVIDIA Tegra 3 processor and an 8GB eMMC NAND flash memory device. When the 8GB eMMC NAND flash memory device for the center display reaches lifetime wear, the eMMC controller will no longer be able to maintain the integrity of the filesystem, causing a failure in some of the center display functions.
Consequence: The eMMC controller wear-out condition can cause the loss of the rearview camera display, defrost/defog control settings, and exterior turn signal lighting, reducing visibility and increasing the risk of a crash.
Remedy: Owners should ensure their vehicles are operating firmware release 2020.48.48.12 or newer, which will alert owners if the eMMC is approaching lifetime wear. Tesla will notify owners, and will replace the VCM daughterboard with one containing an enhanced eMMC controller, free of charge. The recall began March 29, 2021. Owners may contact Tesla customer service at 1-877-798-3752. Tesla's number for this recall is SB-21-21-001.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 19V002000
2019-01-07 · EA15001
Tesla, Inc. (Tesla) is recalling all 2014-2016 Model S vehicles equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the passenger frontal air bag, these inflators may explode due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Tesla will notify owners, and Tesla Service Centers will replace the passenger frontal air bag modules, free of charge. The recall began May 29, 2019. Owners may contact Tesla customer service at 1-877-798-3752. Tesla's number for this recall is SB-19-20-001.
STEERING:ELECTRIC POWER ASSIST SYSTEM · 18V204000
2018-03-29
Tesla, Inc. (Tesla) is recalling certain 2012-2016 Tesla Model S vehicles equipped with Bosch steering racks. The aluminum bolts that attach the power steering gear assist motor to the gear housing may corrode and fracture causing a reduction or complete loss of power steering assist.
Consequence: Loss of power steering assist would require a higher steering effort, especially at lower speeds, which may increase the risk of a crash.
Remedy: Tesla will notify owners, and Tesla Service Centers will replace the steering gear mounting bolts and add a corrosion-preventative sealer, free of charge. The recall began May 7, 2019. Owners may contact Tesla customer service at 1-877-798-3752. Tesla's number for this recall is SB-18-32-002.
PARKING BRAKE · 17V260000
2017-04-19
Tesla, Inc. (Tesla) is recalling certain 2016 Model S and Model X vehicles. The electric parking brake calipers have an internal gear that may be improperly manufactured, possibly resulting in the gear fracturing during parking brake application or release.
Consequence: If the gear breaks during parking brake release, the vehicle will not be able to be moved. If the gear breaks during parking brake application, the parking brake may not adequately hold the vehicle, potentially resulting in the vehicle rolling, increasing the risk of a crash.
Remedy: Tesla will notify owners, and service centers will replace both the left and right electric parking brake calipers, free of charge. The recall began March 6, 2018. Owners may contact Tesla customer service at 1-877-798-3752. Tesla's number for this recall is SB-17-33-002.
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