Switchpack Rebuild and Repair – 1.5 Series

Tesla Roadster Switch Pack — 1.5 Series (VIN < 501) and VIN 501 on up

The Switch Pack is the low-voltage control unit that interprets the cars low voltage switching, and multiple body functions (turn signals, wipers/washer, headlamps, hazards, horn, windows, trunk release, and other auxiliaries). Located behind the center stack/console, it’s subjected to heat cycling, vibration, and occasional liquid ingress.

It was originally made by Eberspächer UK and is part of the Roadster pre-charge interlock loop, so when it fails, it often  shuts down the Roadster, causes isolation issues, or BSM error alerts, and can prevent the Roadster from charging.  These assemblies have been out of production for years; surviving spares are scarce and typically aged.  1.5 series switchpacks are not interchangeable with 2.x switchpacks.

When the Switch Pack degrades, owners may see intermittent or inoperative controls (e.g., wipers that won’t park, erratic turn signals or hazards, inoperative horn/windows, headlights that flicker), nuisance battery drain, or CAN/body controller faults. Because swaps from used 1.5 or 2.x series donors typically insert aged units with deferred or pending issues, a component-level rebuild is the only durable fix, since production of these units stopped a decade ago.

Component-Level Rebuild & Reverse Engineering

We have reverse engineered both types of Switch Packs and offer full board-level repair and rebuild. Our Electronics Engineers service these units in-house:
inspection under magnification, ultrasonic clean, connector refurbishment, and targeted replacement of relay/MOSFET drivers, regulators, capacitors, and cracked solder joints. Known weak points (heat-stressed joints, oxidized ribbon connections, moisture-sensitive areas) are corrected and fortified for long-term reliability.

Each Switch Pack is disassembled, tested on a bench harness, then validated under load. We confirm proper current handling for lamps/motors, verify wiper park logic, turn-signal/hazard flash rate, horn drive, and window/trunk outputs. Final steps include conformal protection and connector pin treatment to mitigate future oxidation.

Common Symptoms We Resolve

• Turn signals or hazards inoperative or intermittent; abnormal flash rate.
• Wipers/washer not responding, no park, or stuck on.
• Headlamps or running lights flicker or won’t latch.
• Horn, windows, or trunk release dead or intermittent.
• Unexpected 12 V battery drain (in 2.x Roadsters from a leaky driver stage.
• Body/CAN errors referencing switch or column/console control faults.

What Our Rebuild Includes

• Disassembly, cleaning, corrosion neutralization, and connector refurbishment.
• Replacement of stressed drivers/relays/regulators/capacitors and reflow of cracked joints.
• Harness/ribbon verification and strain-relief improvements where applicable.
• Bench/load testing of all outputs (lamps, motors, horn) and logic validation (wiper park, hazard/turn cadence).
• Protective conformal coating on sensitive areas; final QC report.

If your Roadster exhibits any of the symptoms above, a professional Switch Pack rebuild is the most reliable path to restore safe, predictable operation without gambling on aging donor hardware. To ship us your failed unit: