2015 Model S 85D Pack Repair Log

Quick Stats

2/16

Modules Tested

4

Active Faults

346 mV

Max SMT Spread

Current Status

Pack dropped and opened in garage. Water confirmed in pyro fuse cavity (cover 1020227-00-C gasket failure). Module 12 and Module 14 TBMM tests: both PASS with 3–4 mV true imbalance. Strong evidence of BMB connector reading issues rather than cell degradation on tested modules.

      Priority next: TBMM Modules 7 (346 mV), 6 (186 mV), 9 (190 mV), and 16 (150 mV). If these also show low true imbalance, pack is likely repairable via connector cleaning + pyro cover replacement.
    

2/16

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 — 2 of 16

2/16

      Module 12: SMT 81 mV → TBMM 4 mV PASS (connector issue, not cells).

      Module 14 (new): Module 22.51 V • cell groups 3.749–3.753 V • imbalance 3–4 mV • temps 16.5–16.8 °C • PASS. Variance confirmed max 1 mV over 23 readings. Another strong indicator that SMT spreads are inflated by BMB connector/water issues.

SMT vs TBMM Comparison

Module	SMT Spread	TBMM mV	Result	Interpretation
12	81	4	PASS	Connector issue, not cells
14	2	3–4	PASS	Healthy — matches low SMT
7	346	PENDING	—	Highest priority
6	186	PENDING	—	High priority
9	190	PENDING	—	High priority
16	150	PENDING	—	High priority
10	150	PENDING	—	Medium
11	150	PENDING	—	Medium
1–5,8,13,15	1–3	PENDING	—	Expected PASS

Pass Criteria

Cell group imbalance ≤ 6 mV = PASS. High ≤ 4.20 V, low ≥ 3.00 V.

Fault Summary

Peak at acquisition: 22 codes. After Toolbox (June 20): cleared to 4 remaining.

Code	Status	Notes
BMS_f107	Re-latches	Hard block on drive/charge — cell voltage sensor inaccurate
BMS_w107	Persists	Warning version of f107
BMS_u018	Persists	SOC imbalance limiting
BMS_a129	Persists	BMB VSH connector — water entry confirmed
BMS_u008, others	Cleared	18 codes cleared via Toolbox + 12V / door / CAN redeploy

Root Cause

Primary: Pyro fuse cover (1020227-00-C) gasket failure → water entry. Confirmed water + corrosion in cavity.

Contributing: deep discharge, 12V failure, charge port door swap without relearn, BMB connector corrosion.

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. GLEV remote: water / possible new pack.

Sept — Picked up; decided DIY pack drop.

Oct — Pack dropped (Vevor jack method), opened. Water in pyro fuse cavity confirmed. Module 12 TBMM: 4 mV PASS. Module 14 TBMM: 3–4 mV PASS (22.51 V, cell groups 3.749–3.753 V, 16.5–16.8 °C).

Next — TBMM priority modules 7, 6, 9, 16. Order pyro fuse + cover.

Related Project Pages

Other sites on 5udyk.com tied to this 85D pack repair and Tesla work.

2015 Model S 85D Pack Repair

Quick Stats

Current Status

Vehicle

SMT Pack Summary (June 17–23, 2026)

Module Voltage Map (SMT Spreads)

Full Module Table

TBMM Progress — 2 of 16

SMT vs TBMM Comparison

Pass Criteria

Fault Summary

Root Cause

Repair Timeline

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