Tesla Model S Battery Replacement 2025: Cost, Specs, Warranty & Aftermarket Options

Tesla Model S Battery Overview

The Tesla Model S battery is one of the most advanced EV battery systems in the world. While it might appear to be a single large battery pack, it actually consists of 16 individual modules, each containing 444 cells, for a total of over 7,000 lithium-ion cells.

This modular design allows for more efficient thermal management and easier servicing, but it also means that performance depends on the health of each individual module. The battery pack is housed in a sealed aluminum case that provides protection, cooling channels, and connection points to the vehicle’s powertrain.

Tesla Model S Battery Design & Technical Specs

Tesla engineered the Model S battery pack with precision electronics that continuously monitor temperature, voltage, and cell balance.

Key Technical Components

• Battery Modules: Each module holds 444 cells organized for optimal current flow and thermal balance.
  
  
• BMS (Battery Management System): The BMS regulates energy distribution, monitors temperature sensors, and ensures that no single module is over- or under-charged.
  
  
• Cooling System: The Tesla Model S battery uses a liquid coolant loop that circulates through all modules. The coolant maintains ideal temperature whether in cold or hot climates, extending battery life and efficiency.
  
  
• Voltage and Capacity: Depending on the model, total capacity ranges from 75 kWh to 100 kWh, producing up to 400 volts of output to power the motors.
  
  

Battery Variant Comparison

Model	Capacity (kWh)	Approx. Range (mi)	Notes
Model S 75	75 kWh	~259 miles	Entry-level battery pack
Model S 85	85 kWh	~285 miles	Balanced power & value
Model S 90	90 kWh	~294 miles	Improved efficiency
Model S 100	100 kWh	~335 miles	Maximum performance and range

This structure allows owners to choose between performance and efficiency, and enables upgrades for longer range.

Common Tesla Model S Battery Problems

Even with its advanced design, the Tesla Model S battery is still subject to wear, environmental damage, and component failure over time.

Here are the most common issues that certified shops encounter:

1. Corroded Capacitors on the BMS
   
   Over years of use, the protective coating on capacitors can degrade, allowing moisture to cause short circuits. Early detection and replacement of these components prevent major system failure.
   
   
2. Voltage Tab Corrosion
   
   Each module connects via thin metal tabs that transmit voltage. Corrosion can loosen or break these tabs, leading to voltage imbalance across modules. Specialized soldering or ultrasonic repair equipment is required for safe restoration.
   
   
3. Faulty Umbrella Valves and Moisture Intrusion
   
   Moisture entering the battery enclosure can trigger oxidation on sensitive electronics. A thorough inspection and replacement of valves ensure the pack remains sealed against humidity and road debris.
   
   
4. Temperature Sensor Failure
   
   Inaccurate readings from a single sensor can cause uneven thermal regulation. Because heat is one of the top causes of EV battery degradation, this issue must be corrected immediately.
   
   

Choosing a repair service that checks for and corrects these systemic problems is vital for long-term reliability.

Aftermarket Tesla Model S Battery Replacement Solutions

Many owners assume that Tesla battery replacement must be done at a Tesla service center. However, aftermarket Tesla Model S battery replacement services can provide equal or better performance at far lower cost.

Why Aftermarket Makes Sense

• Cost Efficiency: Dealership replacements can reach $20,000; aftermarket solutions often cost 30–50% less.
  
  
• Comprehensive Testing: Reputable providers disassemble and cycle-test every module to balance capacity before reassembly.
  
  
• Supercharging Compatibility: Proper programming ensures your vehicle remains eligible for Tesla’s Supercharger network.
  
  
• Warranty Coverage: Trusted shops, like Greentec Auto, offer warranties comparable to factory coverage for added peace of mind.
  
  

When selecting an aftermarket provider, ensure they fully understand Tesla’s cooling system, firmware integration, and BMS programming — these are crucial to maintaining performance and safety.

Tesla Model S Battery Upgrade Options

Upgrading your Tesla Model S battery can dramatically enhance your vehicle’s capabilities.

For example, upgrading from a 75 kWh pack to a 100 kWh pack can extend range by 75 miles or more and reduce total charging time thanks to improved cell chemistry.

Benefits of Upgrading

• Extended Range: Drive farther on a single charge, ideal for long commutes or road trips.
  
  
• Improved Performance: Higher-capacity batteries deliver greater peak power to the motors.
  
  
• Faster Charging: Newer packs are optimized for higher charge rates, reducing downtime.
  
  
• Future Resale Value: Upgraded vehicles retain value longer due to improved specs.
  
  

Greentec Auto can reprogram your vehicle’s onboard systems to recognize the new battery’s energy profile, ensuring full functionality and accurate range display.

Tesla Model S Battery Replacement Process

The replacement process combines precision mechanical work with advanced programming.

1. Vehicle Preparation: The Model S is raised on a lift and disconnected from high-voltage circuits.
   
   
2. Battery Removal: The existing battery pack is unbolted and lowered from the undercarriage.
   
   
3. Inspection and Servicing: The old pack is tested; reusable modules may be reconditioned or recycled responsibly.
   
   
4. Installation of Replacement Battery: A refurbished or upgraded Tesla Model S battery is installed.
   
   
5. Software Programming: The car’s firmware is updated to recognize the new battery type and range capacity.
   
   
6. Cycle Testing: The vehicle undergoes 2–3 full charge/discharge cycles to verify capacity, range, and thermal stability.
   
   

Each step is designed to maintain factory-level performance while meeting strict safety standards.

Tesla Model S Battery Replacement Cost & Savings

Replacing a Tesla Model S battery through Tesla can cost $15,000 to $20,000 depending on capacity and model year.

Aftermarket experts like Greentec Auto provide equivalent performance for 40–50% less, without compromising quality or safety.

What Affects Cost

• Battery Size & Variant: Larger kWh packs cost more but offer greater range.
  
  
• Condition of Existing Pack: Reusable modules lower total replacement cost.
  
  
• Programming & Testing: Software calibration and cycle testing add minimal but necessary labor.
  
  
• Warranty & Support: Extended warranty options increase long-term value.
  
  

By selecting a trusted aftermarket specialist, owners can reduce costs while ensuring a fully tested, warrantied Tesla Model S battery replacement.

Greentec Auto: Trusted Experts in Tesla Battery Replacement

Since 2012, Greentec Auto has been at the forefront of hybrid and EV battery technology, offering solutions that combine engineering precision with affordability.

Why Choose Greentec Auto

• 13 Years of Experience: We began with hybrid systems like the Prius and now specialize in full EV platforms.
  
  
• Extensive Inventory: Over 240 battery types available for Tesla Model S, Model 3, Model X, and more.
  
  
• Nationwide Coverage: 34 locations across the U.S. offer installation and support.
  
  
• Quality Assurance: Every battery is cycle-tested and balanced before installation.
  
  
• Customer Transparency: Detailed quotes, warranties, and technical support provided with each job.
  
  

FAQs

1. How much does a Tesla Model S battery replacement cost?

Typical replacement costs range between $10,000 and $20,000 depending on battery size and vehicle model year. Greentec Auto offers aftermarket solutions that can save you up to 50% compared to dealership pricing.

2. Can I still use Supercharging after a battery replacement?

Yes. Greentec Auto’s properly programmed and tested aftermarket Tesla Model S batteries are fully compatible with Tesla’s Supercharger network.

3. Can I upgrade my Tesla Model S battery to a larger capacity?

Absolutely. You can upgrade from 75 kWh to 100 kWh to gain more range, performance, and efficiency. Our team reprograms your vehicle software to recognize the new capacity accurately.

4. How long does a Tesla Model S battery last?

Most Tesla Model S batteries retain 80–90% of their capacity after 8–10 years. Regular cycle balancing and coolant system maintenance help extend battery life.

5. What is included in Greentec Auto’s warranty?

Each replacement battery comes with a warranty that covers parts and labor for a specified period or mileage, ensuring peace of mind and long-term reliability.

Final Thoughts

Your Tesla Model S battery is the heart of your electric vehicle. When it’s time for replacement, don’t settle for partial repairs or inflated costs.

With Greentec Auto, you’ll receive an expertly refurbished or upgraded Tesla Model S battery replacement backed by proven experience, advanced diagnostics, and nationwide support.

Drive farther, charge faster, and save thousands — all while maintaining Tesla-level performance.

👉 Get your custom quote now at GreentecAuto.com.