2015 Model S 85D Pack Repair Log

Quick Stats

7/16

Modules Tested

4

Active Faults

346 mV

Max SMT Spread

Current Status

Pack dropped and opened in garage. Water confirmed in pyro fuse cavity. Modules 12, 14, 15, 9 & 8 TBMM PASS (3–5 mV) after sense-wire repairs. Module 7 improved from 148 mV to 77 mV FAIL after riveting yellow/orange/green (still thumbs-down, troubleshooting). Module 16 initially FAIL 146 mV (later repaired). Module 9 (bunkhouse with 8) had terminal corrosion + detached wires → now PASS. Priority remaining: Module 6 and finish Module 7.

      Priority next: Finish Module 7 (now 77 mV FAIL after wire repair; SMT 346 mV), Module 6 (186 mV SMT). Module 8 now PASS 4 mV. Pyro fuse: TPN 1053124-00-A / TSN T15E0022094.
    

7/16

To-Do List

Module 12: Bottom orange sensor wire riveted. Post-repair TBMM: 22.51 V • cells 3.749–3.753 V • 4 mV PASS • 15.0/14.9 °C • thumbs-up. Variance over 6.2 min (158 readings): Hi=268 mV (M1 C3), 2 cells >5 mV. White marks on connector plate bottom noted.
Module 9: Green/brown/orange sense wires riveted. Post-repair TBMM: 22.53 V • cells 3.751–3.756 V • 5 mV PASS • 15.2/15.1 °C • thumbs-up. Heavy terminal/busbar corrosion noted (visual). Variance max 1 mV. (Oct 24)
Module 8: Orange/green/brown sense wires riveted. Post-repair TBMM: ~22.50 V • cells ~3.75 V • 4 mV PASS • thumbs-up. Same wire colors as Module 9. (Oct 24)
Module 7: Yellow/orange/green sense wires riveted. Before: ~148 mV FAIL. After: ~77 mV still FAIL (high/low ~3.792 / 3.715 V). Still thumbs-down. Improved but out of spec; no further change on wiggle test. Continue troubleshooting. (Oct 24)
Module 16: Sense wires repaired (previously detached orange/green). Retest confirmed improved.
TBMM remaining priority: Module 6 (186 mV SMT). Finish Module 7 investigation.
Inspect sensor leads & BMS boards on remaining modules (especially those with high SMT spreads).
Address pyro fuse / cover (TPN 1053124-00-A) — water intrusion source.
Continue physical inspection logging as modules are opened.

Vehicle

VIN	5YJSA1H25FF091116
Miles / Cycles	117,988 mi / 1,215 cycles
Pack	1058038-00-F (85 kWh, 16-module)
Supercharging	SC01 free (confirmed)
Acquisition	Copart Akron non-runner

SMT Pack Summary (June 17–23, 2026)

Metric	Value	Notes
Pack voltage	361 V
Cell max / min	3.968–3.970 / 3.622–3.624 V	Static
Imbalance	344–348 mV	No change over 5 days
CAC min / max	208 / 211 Ah	2.70 Ah spread (~90% of nominal)
Temps	61.7–68.9 °F	Uniform

Module Voltage Map (SMT Spreads)

Green = flat (<10 mV) • Orange = elevated • Red = high priority

Full Module Table

Mod	Low V	High V	Spread	Flag

TBMM Progress — 7 of 16

7/16

      Module 12: SMT 81 mV → TBMM 4 mV PASS (connector issue). Post-rivet (orange sense wire): 22.51 V • cells 3.749–3.753 V • 4 mV imbalance • 15.0/14.9 °C • thumbs-up. Variance over 6.2 min (158 readings): Hi=268 mV (M1 C3), 2 cells >5 mV. Physical: looks good; all sensor wires good after orange rivet; white marks on connector plate bottom.

      Module 9: Initial TBMM FAIL 183 mV (detached green/brown/orange sense wires). After riveting: 22.53 V • cells 3.751–3.756 V • 5 mV imbalance • 15.2/15.1 °C • thumbs-up PASS. Variance max 1 mV. Heavy corrosion on terminals/busbars (visual). Sense-wire repair resolved the imbalance.

      Module 8: Orange/green/brown sense wires riveted (same colors as Module 9). Post-repair: ~22.50 V • cells ~3.75 V • 4 mV imbalance • thumbs-up PASS. Clean low imbalance. (Oct 24)

      Module 7: Yellow/orange/green sense wires riveted. Before: ~22.51 V, high/low ~3.827/3.679 V, 148 mV FAIL. After: ~22.51 V, high/low ~3.792/3.715 V, 77 mV still FAIL. Still thumbs-down. Improved after the three wires but remained out of spec; no further voltage change on wiggle test. Continue troubleshooting. (Oct 24)

      Module 14: 22.51 V • 3.749–3.753 V • 3–4 mV • 16.5–16.8 °C • PASS.

      Module 15: 22.50 V • cell groups 3.747–3.751 V • imbalance 3–4 mV • temps 13.5–13.7 °C • variance max 1 mV • PASS. All sensor wires good (top: red/yellow/blue/black; bottom: orange/green/brown).

      Module 16: 22.51–22.52 V • cells 3.681–3.827 V (5:3.681 / 6:3.827) • imbalance 146 mV FAIL • temps 11.7–12.5 °C. Variance stable. Real cell-group imbalance confirmed. Sensor leads: detached orange and green wires on bottom.

SMT vs TBMM Comparison

Module	SMT Spread	TBMM mV	Result	Interpretation
12	81	4	PASS	Connector issue, not cells
9	190	5	PASS	Sense wires detached → fixed by rivet; corrosion visual only
14	2	3–4	PASS	Healthy — matches low SMT
15	1	3–4	PASS	Healthy — matches low SMT
16	150	146	FAIL	Real imbalance — detached sense wires
7	346	77	FAIL	Improved from 148 mV after yellow/orange/green rivets; still out of spec
8	2	4	PASS	Orange/green/brown riveted; clean 4 mV
6	186	PENDING	—	High priority remaining
10	150	PENDING	—	Medium
11	150	PENDING	—	Medium
1–5,8,13	1–3	PENDING	—	Expected PASS

Physical Inspection (Sensor Leads & BMS Board)

Colored boxes = wire color. P = good, F = issue/needs repair, — = not yet checked. Notes in the right column.

Module	Sensor Wires	BMS Board	Notes
12	P P P P P P P	—	Bottom orange riveted (now good). White marks on connector plate bottom. All sensor wires good.
14	— — — — — — —	—
15	P P P P P P P	—	All sensor wires good (top red/yellow/blue/black; bottom orange/green/brown).
16	— — — — F F —	—	Detached orange and green sense wires (bottom). Real imbalance confirmed.
7	— — — — — — —	—	Highest priority (SMT 346 mV)
6	— — — — — — —	—	High priority (SMT 186 mV)
9	— — — — — — —	—	High priority (SMT 190 mV)

Balancing

Use TBMM to balance modules with confirmed imbalance after sense-wire repairs.

Module	Status	Notes
16	PENDING	Repair sense wires first, then retest and balance if still high

Pass Criteria

Imbalance ≤ 6 mV → PASS
High cell ≤ 4.20 V, Low cell ≥ 3.00 V

Fault Summary

18 of 22 codes cleared with Toolbox 3. 4 remaining:

BMS_f107 — Pyro fuse open (or sense issue)
BMS_w107 — Pyro fuse warning
BMS_a129 — Cell imbalance
BMS_a130 — Cell imbalance

Root Cause

Pyro fuse cover gasket failure (cover P/N 1020227-00-C) allowed water into the cavity. This is the source of the f107/w107 and likely contributed to sense-wire issues.

Connector Issue vs Real Cell Imbalance

SMT high spread with TBMM low spread = BMB/connector or sense-wire problem, not cell degradation.

Module 12 example: SMT 81 mV → TBMM 4 mV PASS.

Sense Wire Repair Guide (Riveting Method)

For detached sense wires (e.g. Module 16 orange/green):

Clean the tab and wire end.
Use a small rivet or crimp to reattach.
Confirm continuity and retest with TBMM.

How to choose the balance point

After repair, balance to the lowest healthy cell group or the pack average, then recheck.

Repair Timeline

May 2026 — Purchased Copart Akron non-runner. 22 fault codes.

May — Replaced 12V AGM + charge port door (Heli-Coil).

June 17–23 — SMT readings: 344–348 mV imbalance, healthy CAC 208–211 Ah, static.

June 20 — Toolbox 3: cleared 18/22 codes, firmware 2025.20.6, brief L1 charge (+7 mi). f107 re-latched.

July — Ervine’s diagnostic.

Oct — Pack dropped (Vevor jack method), opened. Water in pyro fuse cavity confirmed. Module 12 TBMM: 4 mV PASS (in-pack). Module 14 TBMM: 3–4 mV PASS. Module 15 TBMM: 3–4 mV PASS (22.50 V, cells 3.747–3.751 V, 13.5–13.7 °C). Module 16 TBMM: 146 mV FAIL (22.51–22.52 V, cells 3.681–3.827 V). Pyro fuse TPN 1053124-00-A logged. Module 16 retested after removal — same 146 mV. Detached orange and green sense wires found on bottom of Module 16. Module 12 physical inspection: looks good overall, sensor wires good except bottom orange needs rivet; white marks on connector plate bottom. Module 12 out-of-pack TBMM retest: 22.51 V, cells 3.749–3.753 V, 4 mV, 13.7–13.8 °C (PASS); variance Hi=23 mV over ~2 min. Module 15 physical: all sensor wires good (top red/yellow/blue/black; bottom orange/green/brown). Module 12 bottom orange sense wire riveted; post-repair TBMM: 22.51 V, cells 3.749–3.753 V, 4 mV PASS, 15.0/14.9 °C, thumbs-up (variance Hi=268 mV over 6.2 min / 158 readings). Module 9 (bunkhouse): visual heavy corrosion on terminals/busbars (Oct 23). Initial TBMM FAIL 183 mV with detached green/brown/orange sense wires. After riveting those wires (Oct 24): 22.53 V, cells 3.751–3.756 V, 5 mV PASS, 15.2/15.1 °C, thumbs-up (variance max 1 mV).

Oct 24 (night) — Modules 7/8/9 sense-wire repairs. Module 9: 183→5 mV PASS (green/brown/orange). Module 8: 4 mV PASS (orange/green/brown). Module 7: 148→77 mV still FAIL (yellow/orange/green); still thumbs-down, no further change on wiggle.

Next — Finish Module 7 investigation (still 77 mV FAIL). TBMM Module 6 (186 mV SMT). Continue remaining modules and pyro fuse work.

Related Project Pages

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2015 Model S 85D Pack Repair

Quick Stats

Current Status

To-Do List

Vehicle

SMT Pack Summary (June 17–23, 2026)

Module Voltage Map (SMT Spreads)

Full Module Table

TBMM Progress — 7 of 16

SMT vs TBMM Comparison

Physical Inspection (Sensor Leads & BMS Board)

Balancing

Pass Criteria

Fault Summary

Root Cause

Connector Issue vs Real Cell Imbalance

Sense Wire Repair Guide (Riveting Method)

How to choose the balance point

Repair Timeline

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