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 severityTypical 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 severityTypical 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 severitySymptoms: 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 severitySymptoms: 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 severityTypical 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 severitySymptoms: 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 severityTypical 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
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.