You may have come across the tripe that EV batteries don’t last very long. According to some folks, EV batteries are so short lived that they will need to be replaced within 2-3 years. And to make things worse, the cost to replace a battery is prohibitively expensive at tens of thousands of dollars!
Of course, NONE of this is true, as we explain below.
How Often Are EV Batteries Replaced?
According to a study done by Recurrent on its database of EVs, Tesla Model 3/Ys have a less than 1% chance of replacement. A Tesla Model S, on the other hand, has a higher 3-4% chance of replacement.
Non Tesla batteries on the other hand seem to have a slightly higher replacement or recall rate. The Nissan Leaf has a replacement rate higher than 5%. This is not surprising as we know that Tesla has some of the best batteries.
However, what’s more interesting is when you compare the battery failure of Teslas to those of gasoline or petrol cars, you will find that a Tesla Model 3 is actually more reliable than a BMW, Audi or Volkswagen! Who would have thought?
How are Tesla Batteries Replaced?
Do not try fixing a high voltage battery by yourself. These batteries are heavy, filled with high voltage circuitry and can cause injury if not handled by an experienced professional. In the event that you find your Tesla battery malfunctioning, the first thing you should do is call Tesla’s service center directly. Tesla will send out a mobile service van to examine the battery and determine if a replacement is required. If the battery warranty hasn’t expired, they will repair the defect free of charge. If the battery is now outside the warranty period, they will offer you an option to either replace the battery with a refurbished version or a completely new set of modules.
Once your car is at the service center, the technician will typically lift up the car up to his or her eye level using a hydraulic lift or joist. This ensures access to the floor of the vehicle that houses the battery. The technician will then unscrew nuts and then lift the car up further to expose the entire battery which can then be fully replaced with a new version.
Tesla provides instructions on the battery replacement process for each of its models. For example, detailed instructions for replacing the High Voltage battery on a Model S can be found here
How Much Does it Cost to Replace a Tesla Battery?
The cost to replace an EV battery is often the source of dread and angst for potential EV owners. Even thought the rate of failure of an EV battery outside its warranty period is low, it is still a cost that must be understood so that owners know what to expect. You can break the cost down into the cost of the battery material and the cost of labor required to replace and reinstall a battery.
The Cost of the Battery
The cost of batteries have declined significantly over the past ten years. The cost per kWh was as high as $300/kWh in 2015 but are now firmly in the $100 – $150/kWh range. What’s more, battery companies such as CATL are now projecting that costs will decline to $50/kWh which will make replacing batteries cheaper than replacing an engine.
Labor Costs
It takes anywhere from 5 – 15 hours of labor for a professional technician to replace a battery. This assumes that the technician is experienced and has the infrastructure and tools required to replace larger sized batteries. If you take your car to a technician or service center that has very little experience, don’t be surprised if the car takes forever to be fixed.
| Tesla Model | Variant | Approx. Weight | Approx. Battery Capacity | Cost Range ($50/kWh – $100/kWh) |
|---|---|---|---|---|
| Model 3 | Standard Range Plus | ~900-1,000 lbs | ~50-55 kWh |
|
| Model 3 | Long Range | ~1,060 lbs | ~75-82 kWh |
|
| Model Y | Long Range | ~1,100 lbs | ~75-82 kWh |
|
| Model Y | Performance | ~1,150 lbs | ~75-82 kWh |
|
| Model S | Long Range | ~1,200 lbs | ~100 kWh |
|
| Model S | Plaid | ~1,300 lbs | ~100 kWh |
|
| Model X | Long Range | ~1,500 lbs | ~100 kWh |
|
| Model X | Plaid | ~1,600 lbs | ~100 kWh |
|
| Cybertruck | Various | ~1,800-2,000 lbs | ~100-200 kWh |
|
The table above provides cost estimates for replacing the batteries of various Tesla models. The lower end of the range assumes a $50/kWh cost while the higher end assumes a $100/kWh cost. In addition to the cost per kWh, the size of the battery is a significant factor. Needless to say, the bigger the battery gets, the more expensive it gets to replace a battery. A model 3 battery replacement should be cheaper than a cybertruck battery replacement.
Modularity and the Future of Battery Repair
All of the above estimates contemplate the complete removal of the entire battery. This doesn’t have to be the case. In a lot of cases, it could very well be that only certain modules or cells are affected, resulting in the technician having to replace just that particular module.
Now, not many technicians have the skillset to replace an entire battery, let alone replace modules within a battery. But as EVs increase in market share, and technicians build their skillset, batteries will be diagnosed and replaced at the modular level, resulting in even lower costs.
For example, a Tesla Model 3 Standard Range battery would have 3 or 4 modules. Replacing a module instead of the battery would require just a third or a quarter of the material cost of an entire battery. This is still a long way away but it will almost certainly happen as EVs become more and more prominent!