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http://www.megamotorrepairs.co.uk/

Megaev - Tesla Repair Specialists, Apps Court Farm, Hurst Road, Walton-on-Thames (2026)

02/10/2026

𝗧𝗲𝘀𝗹𝗮 𝗠𝗼𝗱𝗲𝗹 𝟯 – 𝗥𝗲𝗮𝗿 𝗗𝗿𝗶𝘃𝗲 𝗨𝗻𝗶𝘁 𝗕𝘂𝘀𝗵𝗶𝗻𝗴𝘀

This Model 3 came in for a health check, with some routine suspension work expected.

Part of our initial assessment is to drive the cars around the workshop, where we can reproduce suspension noises and feel how the car behaves. This is particularly handy when diagnosing air suspension rattles on the Model S and X.

As soon as this car started to move, we heard a distinct thud from the rear.

The cause was failed rear drive unit bushings. On higher-mileage Model 3s, the rubber in these bushings can crack and tear, allowing the drive unit to move excessively under acceleration. As well as causing the thud, this movement can put extra strain on the connected wiring and coolant hoses.

The bushings themselves are relatively inexpensive, but replacing them involves considerably more work. For this repair, we safely isolated the high-voltage system, disconnected the coolant hoses and removed the complete rear subframe, followed by the drive unit.

A generic bushing press kit wasn’t enough for this job either. There is limited space around the driver’s-side bushing, and the bushings are an extremely tight fit, so the correct tooling makes a real difference.

After replacing the bushings, reassembling everything and completing the required thermal system test, the thud is gone: The drive unit is properly secured in the subframe again.
As always after subframe removals, wheel alignment was required so we quickly utilised our Hunter aligner, sorted the suspension geometry and the car is quiet again 👍🏼

24/08/2026

Tesla Model S P100D – Full AC & Thermal System Overhaul

This P100D visited us with several thermal system related issues. Radiator shutter alerts were present and the air conditioning performance had also noticeably degraded.

Having had around 80 AC system repairs this year alone we knew it wasn’t going to be just an AC regas. It never is. Refrigerant isn’t consumed in any way – it circulates around a sealed system. If the refrigerant level is low, it has escaped somewhere.

Upon checking the condensers we discovered the coolant radiator was in very poor condition and looked close to developing a leak so we discussed replacement with the customer.
A visual inspection also confirmed multiple leaks in the AC system, with both condensers showing signs of leakage.

Interestingly, the car had been regassed relatively recently.

This fits a pattern we’ve seen repeatedly throughout the summer:

• The AC stops performing properly
• the car goes in for a regas
• the system passes a vacuum test
• it’s recharged and declared leak-free.

Then a few days, weeks or months later, the AC performance starts dropping again.

The problem is that a vacuum test can quite easily give a false sense of security. A system which holds under vacuum can still leak when subjected to operating pressure.

We’ll go into this in more detail in a separate video.

Condensers are often the first suspect on Model S and X, particularly once they’ve suffered years of corrosion and road debris, but they’re definitely not the only possible leak point.

We regularly find leaks around seals and pipe joints, and occasionally around pipe compression fittings or the AC compressor itself.

Because of this, when we receive a car with unexplained refrigerant loss or degraded AC performance, we now carry out a full high-pressure nitrogen test using our purpose-built test rig.

This allows us to test the system under positive pressure and find small leaks which can otherwise be extremely difficult to identify.

We’ve also put together a complete AC seal kit using genuine Tesla seals, allowing us to replace the ageing seals throughout the system while it is apart rather than fixing one leak and potentially leaving another one behind.

And this P100D was a good example of why.

Alongside the leaking condensers, we found additional seal leaks and a corroded, cracked crimped fitting on one of the high-pressure AC pipes. The leak from this fitting was extremely small and only became apparent once the pressure approached approximately 20 bar.

The chiller also had a leaking sealing ring, which was replaced as part of the overhaul.

The front end was stripped down, the deteriorated radiator and condensers were replaced, all the AC seals were renewed and the system was pressure tested again before being evacuated and correctly recharged.

Once everything was reassembled, we also carried out the required radiator shutter calibration through Tesla Toolbox.

A considerably bigger job than an AC regas – but the result is a properly repaired, pressure-tested and fully operational thermal system. 👍🏼

20/07/2026

🔧 Model 3 Heat Pump Failure - Why One Failed Compressor Can Easily Turn Into a £3,000-£5,000 Repair

This Model 3 arrived with an “Air Conditioning Unavailable” alert and no cabin cooling. What initially appears to be a simple A/C fault can quickly become one of the most expensive thermal system repairs on a heat pump-equipped Tesla.

Although we suspected a failed electric compressor, we never replace expensive parts based on assumptions. After carrying out a full thermal system diagnosis, we confirmed the compressor had suffered an internal mechanical failure.

Unfortunately, this is becoming an increasingly common issue on heat pump-equipped Model 3s.

Once the compressor starts breaking up internally, it sends fine metal particles throughout the refrigerant circuit. Those particles don’t just remain inside the compressor - they contaminate the entire refrigerant system, including the Supermanifold, which then also requires replacement.

Fortunately, the evaporator inside the dashboard could be professionally flushed rather than replaced. This is one of the most critical parts of the repair. If any contamination remains in the system, or the correct amount of compressor oil isn’t restored afterwards, the replacement compressor can fail again very quickly.

When we removed the radiator pack, we found nearly half of the cooling surface blocked with leaves and road debris. While this wasn’t necessarily the root cause of the failure, restricted airflow increases operating temperatures and places additional load on the compressor. We also found evidence suggesting the Supermanifold wasn’t regulating the system as efficiently as it should, forcing the compressor to work even harder. We discussed the options with the owner and decided to replace the radiator as well instead of trying to clean it .

The completed repair included:

✅ New electric compressor
✅ Correct compressor type programmed using Tesla Toolbox
✅ New Supermanifold assembly
✅ New radiator
✅ Complete refrigerant circuit flush
✅ Evaporator flush
✅ Radiator pack removed and thoroughly cleaned
✅ System vacuum tested and recharged with the correct refrigerant and oil quantity
✅ Thermal performance verified using Tesla Toolbox

Can this be prevented?

Unfortunately there is no guaranteed way to prevent heat pump failures, but a few simple maintenance items can significantly improve the chances of a long service life:

• Don’t ignore thermal or HVAC alerts. Any fault affecting the thermal management system can increase compressor workload if left unresolved.

• Clean the radiator pack regularly (ideally every year). Keeping airflow unrestricted reduces thermal stress on the system.

• Replace the Supermanifold filter approximately every 18-24 months and inspect it for signs of metallic contamination.

• Consider an A/C service every 2-3 years. Correct refrigerant quantity is important because low refrigerant levels force the compressor to work much harder to achieve the requested cabin temperature.

Unlike a conventional A/C system, the heat pump-equipped Model 3’s thermal management system works almost continuously throughout the year. It is responsible for cooling and heating the cabin, cooling the Autopilot computer, conditioning the battery and managing drivetrain temperatures.

07/07/2026

𝗠𝗮𝗷𝗼𝗿 𝘄𝗼𝗿𝗸𝘀𝗵𝗼𝗽 𝘂𝗽𝗴𝗿𝗮𝗱𝗲 𝗰𝗼𝗺𝗽𝗹𝗲𝘁𝗲𝗱

The past two weeks have been extremely busy behind the scenes at MegaEV, but today we finished a major workshop upgrade.

We replaced our large commercial lift with a clear-floor two-post lift, giving us a lot better access underneath the cars.

This makes a big difference when working on coil-sprung Model S and Model 3s and especially when carrying out HV battery removals.

We have also invested in a dedicated battery removal platform, allowing us to remove and refit Tesla battery packs in a much more controlled way .

But the biggest upgrade is this:

We have replaced our smaller two-post lift with a 4-post alignment ramp and a Hunter HawkEye Elite wheel alignment machine.

We have been struggling to find a reliable local alignment centre with the right equipment, the right setup, and the right understanding of Teslas — so we decided to bring it in-house and offer a premium alignment service to all Tesla owners .

This means we can now carry out proper alignment checks and adjustments ourselves, especially after suspension and steering repairs or motor removal work which requires subframe removal.

It also gives us better control over the full repair process, instead of repairing the car here and then relying on someone else to finish the job properly.

We are currently working through a large backlog due to the time it took to have everything fitted, set up, and calibrated, but we will be opening up new alignment bookings soon.

Another big step forward for the workshop.

MegaEV – Tesla Repair Specialists London and Surrey

30/05/2026

We received a phone call on Friday afternoon from a Tesla Model X owner who was stranded at the Heathrow Supercharger after his charge port stopped working correctly.

Fortunately, he had enough range left to make it to our workshop, where we were able to diagnose the fault straight away.

The motorised charge port door was no longer reporting its position correctly, meaning the car could not determine whether the charge port was open or closed and would not allow charging.

As always, we attempted calibration first, but unfortunately the fault remained. Luckily, we had a new charge port door assembly in stock, allowing us to begin repairs immediately rather than waiting for parts to arrive.

During disassembly we discovered the root cause of the problem. The connector between the charge port door and the charge port itself had suffered from water ingress. Further investigation revealed the cause to be a blocked chassis drain beneath the charge port area, allowing water to collect around the connector.

Fortunately, we were able to clean and restore the connector, saving the original charge port. We also cleared the blocked drain to prevent future water ingress. Only the charge port door assembly required replacement, avoiding a significantly more expensive repair.

A few hours after the initial phone call, the vehicle was repaired, tested and charging normally again.

The owner was genuinely surprised by the turnaround time and wasn't expecting to be back on the road the same day.

21/05/2026

Tesla Model S 85D → 100kWh battery upgrade ⚡

Our extremely low mileage SC01 Model S 85D received a serious upgrade today.

With just 35,000 miles on the clock, the condition underneath is about as close to factory fresh as you’ll see on a 10year old car😎

The original 85kWh battery pack was removed and replaced with a much newer 2023-spec 100kWh pack.
👌

Besides the increase in usable capacity and extra range, the newer pack also brings significantly improved charging performance compared to the original 85kw pack .

A nice upgrade for this Model S — now with more range, faster charging and still keeping the valuable SC01 free Supercharging 👌⚡

26/04/2026

Complicated Coolant Delete: Solved!

This 2017 Model S came in for a health check. Being a rear-wheel drive - which uses Tesla’s Large Drive Unit - we checked the speed sensor for coolant ingress—and found it so we booked the car in for coolant delete. Upon disassembly we run into a major issue : the high-voltage cables were completely seized. This car is a late RWD with the latest generation HV harnesses which meant the motor HV cables join into the HV rapid mate connector, this limits the space we have and its not possible to disconnect from the other end like it is on older models .
Without enough space to lift the motor and no option to disconnect the motor HV cables from the car we had to come up with a cost effective plan to solve the issue . We removed the HV battery and RapidMate connector, freeing just enough room and giving enough slack to the motor HV harness to be able to work on it . Inside, we confirmed coolant had reached the drive unit. We disassembled the motor, cleaned the stator, replaced the rotor bearings, applied the coolant delete kit, reassembled and measured resistance . Now, this Model S is back on the road—problem solved and another LDU saved before it’s too late .

23/04/2026

Tesla Model X Raven air strut refurbishment

This Tesla Model X Raven came in with a heavy air strut leak.

Where possible, we prefer refurbishing the original Tesla struts rather than fitting low-quality aftermarket units. Brand new genuine struts are expensive, and in many cases the original unit is still well worth saving.

The shock absorber inside these air struts is a robust Bilstein unit and very rarely fails. What usually causes the problem is corrosion on the lower collar and - in some cases - a loosened top nut inside the strut.

On this one, we removed the collar, cleaned everything up properly, replaced the seals, reassembled the unit, carried out a leak test, refitted the strut, cleared the air spring leak alert and calibrated the suspension system.

Another original Tesla component repaired properly and back in service.

12/04/2026

This Tesla Model X arrived with all air suspension fully dropped. The customer had visited multiple garages, including Tesla, and had been told they needed a valve block and compressor replacement. They also expected a possible air strut leak. Instead of jumping into replacing parts, we used Tesla’s Toolbox diagnostic software to dig deeper. Toolbox showed that the air suspension ECU wasn’t responding—no CAN communication. We removed the TAS ECU , checked the wiring and found that the loom had rubbed against a coolant hose, cutting power to the ECU. Instead of a costly loom replacement (which likely would have been thousands as Tesla is very strict on allowed loom repairs ), we repaired the wiring and reinforced/re-routed the affected area to future proof the repair . Once restored, the ECU came back online, and the suspension worked immediately. We then leak-tested all air struts—no leaks. The compressor and valve block were absolutely fine. In just a few hours, we had them back on the road without unnecessary part replacements!

01/04/2026

𝗧𝗲𝘀𝗹𝗮 𝗽𝗮𝗿𝘁𝘀 𝗮𝘃𝗮𝗶𝗹𝗮𝗯𝗹𝗲

As part of our repair work we regularly have Tesla donor vehicles in stock.

We currently have a Tesla Model X 100D and a Tesla Model S 85D available for parts.

The Model X has front left damage but still has many good parts available. Most other parts are available including Carbon interior trim, rear panels, tailgate, doors, drivetrain and electrical components, subject to inspection.

The following Model X parts are not available:
• HV battery pack (reserved for a customer)
• All airbags
• Windscreen
• Front bumper
• Front left corner components / body panels
• Air suspension struts

The Model S has already been partly dismantled and what you see in the photos is what remains plus a rear bumper . There are still good parts available including black leather seats, interior trim, rear suspension and drivetrain components, electrical modules and various mechanical and body parts.

If you are looking for a part for a Tesla Model S or Model X, please email [email protected] with what you need and ideally the VIN/specification of your car.

Please note, we won’t have the capacity to reply to requests here in messenger.

Megaev - Tesla Repair Specialists

02/10/2026

24/08/2026

20/07/2026

07/07/2026

30/05/2026

21/05/2026

26/04/2026

23/04/2026

12/04/2026

01/04/2026

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Monday	9am - 5pm
Tuesday	9am - 5pm
Wednesday	9am - 5pm
Thursday	9am - 5pm
Friday	9am - 5pm