Federal security officials are investigating allegations of a damaged cooling system installed on an early Tesla model vehicle.
Tesla installed leak-prone coolant tubes on Model S vehicles starting in 2012, according to an internal email quoted by People in business last week. The Times reviewed copies of emails and other documentation showing tubes installed from 2012 to 2016, where Tesla decided on a supplier and began producing tubes at home.
The National Road Traffic Safety Administration, in a statement to The Times, said “is very aware of the report on this issue and will take action if appropriate based on facts and data.” The agency also reminded car manufacturers that they were required “to notify the agency within five days of the manufacturer becoming aware of safety related defects and making a recall.” Tesla never seems to issue such notifications.
Tesla did not respond to requests for comment.
The National Transportation Safety Board also issued a statement to The Times. The council said “at the final stage of the completion of the Special Investigation Report based on the investigation of several accidents involving electric vehicles and battery fire / thermal events generated.”
The NTSB is an investigative agent which, unlike NHTSA, has no law enforcement powers. When investigating electric vehicle fires, the council said it was considering “whether existing mechanical problems or material damage contributed to the accident or the severity of the accident.”
The Business Insider article said that Tesla knew the battery cooling system installed in the Model S car had a defective design but continued to sell the car, citing internal documents and “three people who were aware of the problem.”
Cooling tubes, sourced from Chinese companies, are vulnerable to cracks and small holes, according to third-party tests conducted by the IMR Test Lab in upstate New York, Business Insider reported. The Times has reviewed the same documentation.
Sources told Business Insider that the final fittings on the coolant tube often did not quite match the connection to the car and had to be forced into position – sometimes, internal emails showed, with a hammer. A source with firsthand knowledge of the matter told The Times the same thing, asking not to be identified for fear of retaliation by Chief Executive Tesla Elon Musk.
Although Tesla used the same supplier based in China for four years, it is unclear whether and when the cooling tube problem was corrected before Tesla brought manufacturing at home in 2016. Without information from the company or safety regulator, it is impossible to find out how many cars were affected.
It is also unclear whether the problem affects Model X, which uses the same cooling system. Model X production begins in 2015.
The Tesla Model 3 uses a different and more efficient cooling system that removes the curved coils on the Model S and Model X.
The battery fire expert said Flammable glycol coolant in the Model S system can cause or worsen battery fires if the liquid or residue touches the damaged battery cell after an accident. In a phenomenon known as thermal escape, one burning battery can spread to other battery cells in a vehicle, which causes a greater fire.
Although it is unclear how common electric car fires are, there are some media reports about the Tesla fires in the months leading up to May 2019, when Tesla began to limit the cost of the Model S to 80% of capacity at the company’s Supercharger station. The closer the battery gets full, the more heat it gets. Several fires were reported to occur after the accident; the other it seems spontaneously combust.
Last November, NHTSA said it was investigating potential defects in Tesla batteries. The agency declined to say whether the alleged cooling tube leak was part of the investigation or was being seen separately.