2016 Tesla Model X transmission problems

POWER TRAIN

I own a 2016 Tesla Model X P100D equipped with the Large Drive Unit (LDU). The component that fails is the rotor coolant seal in the rear drive unit motor. Coolant leaks internally into the motor and inverter, causing bearing wear, corrosion, isolation faults, and eventual complete drive unit failure. The affected drive units are still installed and available for inspection upon request. This defect puts my safety and the safety of others at risk because it can cause sudden loss of propulsion (especially at highway speeds), power reduction, or total drivetrain shutdown, potentially leading to a crash. Coolant in high-voltage areas also raises electrical fault/fire risks. The problem is widely reproduced and confirmed: Tesla service centers are familiar with it and replace failed units with updated “-U” revisions that include a coolant bypass. Independent EV shops confirm the exact root cause (rotor seal failure) via encoder inspections showing coolant intrusion and through disassembly. This is a documented pattern failure in all 2012–2020 LDU vehicles. No police or insurance inspections have occurred yet, as no crash or total failure has happened. Tesla is aware of the recurring issue through service records on similar vehicles. Early symptoms before full failure typically include rear motor whining/grinding (especially under load), reduced power warnings, “Rear Drive Unit Fault” messages, and visible coolant on the speed sensor. These can appear gradually. My vehicles have not yet experienced total failure, but the defect is known to be inevitable. I am proactively monitoring encoder sensors. Because this is a systemic design defect affecting thousands of vehicles with clear safety implications, I request NHTSA open an investigation and require Tesla to issue a recall for free repairs/replacements on all affected 2012–2020 LDU vehicles.

NHTSA complaint #11735432 — an unverified report by a vehicle owner.

POWER TRAIN

To Whom It May Concern, My name is [XXX] , and I am writing regarding unresolved issues with my 2016 Tesla Model X (VIN: [XXX] ). Despite multiple service visits, extensive repairs, and approximately $8,000 in costs, my vehicle remains undrivable and presents significant safety concerns. I initially brought my vehicle to the Tesla Service Center in Richmond, Texas, for motor-related issues. I was informed that mismatched tires and front-end components were contributing to the problem, and repairs were completed. However, the original issue persisted. Subsequent visits for additional repairs also failed to resolve the problem, and new safety concerns emerged. Complicating matters, the Richmond Service Center has since closed, and its staff were terminated. When I contacted the Westchase Service Center, Manager Andrea P. informed me that no resolution or agreement could be reached. I have attached the following invoices for your review: Invoice #[XXX], dated April 26, 2024 Invoice #[XXX], dated November 9, 2023 I am requesting the following: A full review of my service history and unresolved issues. Immediate repairs to address motor and safety concerns at no additional cost. A clear explanation of Tesla’s policies regarding unresolved repairs, especially with closed service centers. This situation has caused financial and personal hardship. I urge Tesla to address these issues promptly to restore my confidence in your brand. Please contact me at [Your Phone Number] or [Your Email Address] to discuss this matter. Sincerely, [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11632748 — an unverified report by a vehicle owner.

POWER TRAIN

I initially brought my vehicle to the Tesla Service Center in Richmond, Texas, to address issues involving the motor. During this visit, I was informed that mismatched tire sizes and worn parts in the front end were contributing to the problem. The service center proceeded with repairs, charging me for the work. However, the original issue persisted after I picked up the vehicle. Despite multiple follow-up appointments and additional repairs, the problem was never resolved.

NHTSA complaint #11632757 — an unverified report by a vehicle owner.

POWER TRAIN

While driving on city streets at very low speeds, error messages starting popping up on the screen "Vehicle may not restart/Service is required". We somehow made it home by restarting the computer and driving home at low speeds. At freeway speeds, this would have been catastrophic. We were able to make an appointment with the Tesla service center and found this to be due to the battery coolant heater to be internally shorted which in turn was because the large rear drive unit had an internal coolant leak. This required a very expensive $8k replacement of the large rear drive unit and the heater. A search in the blogs has yielded this to be a design and manufacturing issue. Specifically the blogs say: "the rear motor used in the early Teslas has a design flaw and will need a very expensive repair/replacement but what does that actually mean? Many Model S and Model X produced between 2012-2020 have the Large Drive Unit (LDU) with the fatal coolant seal flaw where the seal around the rotor shaft will leak coolant into the motor (Reference 1). They will ALL leak eventually. Tesla tried many things over the years to keep this seal from leaking but finally gave up and developed ‘Revision U’ in the fall of 2022 which deletes the coolant from the rotor but maintains the coolant to the inverter, stator and the ‘flyover’ tube cooling the gearbox". This means that the same problem even after the replacement, will happen again soon. I am writing to request you to send out a recall to all owners of these cars, and to have Tesla refund us for the cost of replacement of the drive unit and for Tesla to install the bypass as some aftermarket vendors (Reference 2) have started doing. Reference: 1) [XXX] 2) [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11631654 — an unverified report by a vehicle owner.

POWER TRAIN

The suspension (the front half shaft) has repeatedly failed and has been replaced multiple times by Tesla. First it was replaced under warranty and now we are paying for it as it is no longer covered under the warranty. The part failure is a safety concern as it has lead to unstable handling, nearly resulting in a crash several times. The parts have always been discarded by Tesla but a full explanation of the problem is here: https://n2itive.me/ No warning lamps or messages appear as it happens every time you accelerate, and sometimes the vibrations are so severe that it affects the handling of the vehicle severely.

NHTSA complaint #11517670 — an unverified report by a vehicle owner.

POWER TRAIN

Under acceleration the Model X has significant front-end vibration. Had the half-shafts replaced 3 years ago but the problem persists.

NHTSA complaint #11480426 — an unverified report by a vehicle owner.

POWER TRAIN

The car started giving error messages of systems failing one after another on the highway. It slowed down instantly as if someone pressed the brakes and I could not accelerate. Obviously I did not press the brakes. There were a lot of vehicles behind me and this could have easily caused an accident putting a lot of people at risk. I had to get off the highway asap and get the car towed. The error messages included charge port disabled, automatic emergency braking is disabled, power reduced, traction control disabled, stability control disabled, cruise control disabled, power reduced. Tesla diagnosed and confirmed this being an issue with the onboard charger being faulty and replaced that with charge port itself for a total of $3727.60. They refused to cover any part of this which I think should have been taken care of by the company.

NHTSA complaint #11467551 — an unverified report by a vehicle owner.

POWER TRAIN

MCU computer has failed multiple times, including one time, middle of a very hot summer day, turning on high heat and rolling up windows, until computer rebooted (seemed like forever), while on the freeway. Tesla later notified us of a recall of the MCU, but repeatedly denied our claim, even though they admitted the MCU was the culprit, "just 'cause". The steering is greatly affected by front motor and its half-shafts. Had repaired right before warranty expired, but the problem remained. Tesla techs all warned us that it would happen again, which it did shortly after, and Tesla refused to repair it again, except to replace the failed components with identical components, all at our cost (thousands of dollars). Tesla techs said that the problem was a notoriously bad design of the half-shafts. They said it was fixed in newer front drive units, but that our only option was to keep replacing the defectively designed parts. When it has this problem, the car wants to steer left or right, but never straight ahead, and can pull suddenly to one side, making driver appear to be drunk from the sudden left-right-left-right motions. Tesla experts have told us that the only fix is to buy a new Tesla.

NHTSA complaint #11442201 — an unverified report by a vehicle owner.

POWER TRAIN

THE VEHICLE STARTED TAKING LONGER TO START UP ABOUT A FEW MONTHS AGO. THEN THE SYSTEM NEEDED TO BE REBOOTED ON A REGULAR BASIS TO BE FUNCTIONAL. AT ONE POINT THE MAIN SCREEN THAT CONTROLS ALL THE SAFETY AND VISIBILITY FEATURES OF THE VEHICLE STOPPED WORKING AND THE VEHICLE WOULD TAKE UP TO 5 MINUTES TO START UP. AFTER DOING SOME RESEARCH THIS IS A COMMON ISSUE WITH TESLA'S OLDER THAN 2018 WHERE THEY ENCOUNTER AN "EMMC FAILURE" OF THE MCU. THE DEFECT OF THE MCU WAS ADDRESSED WHEN TESLA REPLACED THE MCU IN ITS VEHICLES IN 2018. THIS SHOULD BE TREATED AS A RECALL DUE TO THE DESIGN FLAW OF THE MANUFACTURER. THE MCU CONTROLS ALL THE SAFETY FEATURES OF THE VEHICLE AND THE REAR VIEW CAMERA. WITHOUT THE MCU IT MAKES IT EXTREMELY DIFFICULT TO HAVE THE VISIBILITY NEEDED TO GO IN REVERSE.

NHTSA complaint #11366765 — an unverified report by a vehicle owner.

POWER TRAIN

THE MCU (THE CAR'S CENTER SCREEN) WOULD NOT TURN ON. THE CENTER SCREEN CONTROLS EVERYTHING IN THE CAR INCLUDING ALL THE UPDATES. SINCE THE CENTER SCREEN DIDN'T WORK, AND UPDATE WAS NOT ABLE TO PASS THROUGH, AND IT ESSENTIALLY MADE THE CAR NOT DRIVABLE. THE CAR WAS IN THE TURN OFF MODE AND WOULD NOT TURN ON.

NHTSA complaint #11330716 — an unverified report by a vehicle owner.

POWER TRAIN

ATTEMPTED TO MERGE ONTO A FREEWAY FROM A STOP SIGNED PARALLEL ENTRANCE. AFTER A VEHICLE IN THE FREEWAY LANE HAD JUST PASSED AND THERE WAS ADEQUATE SPACE BEFORE THE NEXT VEHICLE, I ATTEMPTED TO ACCELERATE RAPIDLY FROM THE FULL STOP. THE VEHICLE ACCELERATED FOR ONLY A VERY BRIEF PERIOD, ENOUGH TO GET IT INTO THE LANE AT MAYBE 10MPH BEFORE THE ACCELERATION CUT OUT COMPLETELY AND A VEHICLE COLLISION WARNING AND AUDIBLE ALERT APPEARED ON THE SCREEN IN FRONT OF THE DRIVER. THERE WAS NOT ACTUAL COLLISION THREAT PRESENT AND I TRIED PRESSING THE ACCELERATOR PEDAL REPEATEDLY TO AVOID BEING HIT IN THE REAR BY THE NEXT VEHICLE COMING FROM BEHIND AT FULL FREEWAY SPEED. THE VEHICLE BEHIND ME CHANGED LANES AND WENT AROUND ME TO AVOID AN ACCIDENT. AFTER A FEW SECONDS THE WARNING WENT AWAY AND I WAS ABLE TO ACCELERATE NORMALLY TO FREEWAY SPEED. THIS SAFETY FEATURE SEEMS EXTREMELY DANGEROUS FOR SEVERAL REASONS: * IT INCORRECTLY SENSES THAT A COLLISION WILL OCCUR WITH ACCELERATION IN SOME INSTANCES * IT DISABLES USER CONTROL OF THE VEHICLE (ACCELERATION) * IT DISABLES THAT CONTROL FOR AN EXTENDED PERIOD OF TIME EVEN AFTER THE FALSE THREAT IS NO LONGER DETECTED * IT ALLOWS SOME MOVEMENT BEFORE DISABLEMENT CREATING A SITUATION WHERE THE VEHICLE IS PUT IN HARM'S WAY WITHOUT ANY ABILITY TO SAFELY ACCELERATE AWAY FROM AN IMPENDING ACCIDENT. HAD THE VEHICLE NOT MOVED AT ALL, THERE WOULD HAVE BEEN INCONVENIENCE BUT NO RISK * THERE IS NO ABILITY IN THE CURRENT SOFTWARE TO DISABLE WHAT I BELIEVE TO BE UNSAFE FUNCTIONALITY INTENDED FOR SAFETY * THERE IS NO DOCUMENTATION TO INDICATE THAT THE CAR HAS THIS UNUSUAL FUNCTIONALITY I HAVE DISCUSSED THE ABOVE ISSUES WITH TESLA MOTORS SUPPORT AND THEY HAVE REVIEWED THE DATA LOGS FOR THE VEHICLE AND BELIEVE IT IS FUNCTIONING NORMALLY AND THAT THIS BEHAVIOR IS AS INTENDED BY DESIGN. MY INITIAL VEHICLE POSITION IS IN YELLOW IN THE IMAGE.

NHTSA complaint #10882841 — an unverified report by a vehicle owner.