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NormalModel SModel X1000-3000 USD

Model S/X 100 kWh: voltage sense harness tab failures

On 100-kWh batteries, voltage sense harness/tab failures on modules occur → BMS errors, pack shutdown. What to do and how much it costs in Belarus.

Battery · 100
Drivetrain · RWD, AWD
Updated · 2025-09-16

Symptoms

  • BMS_w107/BMS_f107 errors and related sensor/measurement circuit codes.
  • Inability to charge/drive, mismatch between total voltage and the "sum by bricks".

The essence of the problem

In V2 100-kWh packs, thin contact "tabs"/harnesses are used to read voltage from cell groups. Due to vibrations, thermal cycling, or impact, contacts can detach → the BMS loses correct readings.

Solutions

  • Diagnostics of modules, finding the defective harness.
  • Restoration/resoldering/replacement of the harness (difficult and requires experience).
  • With multiple detachments — module/pack replacement.

Belarus budget

  • Removal/diagnostics/local repair: ≈ $1 000–3 000 (more often ~$2 000).

Links

Sources

  • sites.google.com
    https://sites.google.com/view/teslahvbattery/the-repair/v2-pack-sense-wire-repair
  • reddit.com
    https://www.reddit.com/r/TeslaModelS/comments/1fymqev/voltage_sense_harness/
  • teslamotorsclub.comarchive
    https://teslamotorsclub.com/tmc/threads/tesla-model-s-2014-hv-battery-issue.284018/page-4
  • static.nhtsa.gov
    https://static.nhtsa.gov/odi/tsbs/2022/MC-10226577-9999.pdf

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