These are just some of the items analyzed and diagnosed for functionality:
Neoprene Rubber Cooling DuctThe 2.x Roadsters rely on a Neoprene Rubber Cooling Duct which channels fan induced cooling air directly into the Power Electronics Module (PEM).
Aging and years of use result in neoprene rubber breakdown often resulting in fissures and cracks which reduce the airflow to this vital electronic modules (PEM).
In addition, the original mounting method was nylon tiewraps which eventually snap, and this cooling duct becomes untethered. We replace these with stainless steel clamps.
2.x PEM Cooling FanThe 2.x Series Tesla Roadster’s Power Electronics Module relies on a pair of DC brush-type PEM Cooling Fans to move air through the PEM heat sink. These motors use carbon brushes and sleeve/ball bearings that wear over time from heat, dust, and continuous cycling. As the bearings dry out and the brushes shorten, the fans can become noisy, slow down, or seize entirely—reducing airflow and allowing temperatures inside the PEM to climb. To protect the electronics and avoid sudden thermal shutdowns, these cooling fans should be treated as a consumable service item. Under normal use, replacement every ~5 years (or sooner in hot, dusty, or high-mileage environments) is recommended as part of preventive maintenance.
The 1.5 Series Tesla Roadster’s Power Electronics Module relies on one DC brush-type Cooling Fans to move air through the PEM heat sink, and another to cool the drive motor. These motors use carbon brushes and sleeve/ball bearings that wear over time from heat, dust, and continuous cycling. As the bearings dry out and the brushes shorten, the fans can become noisy, slow down, or seize entirely—reducing airflow and allowing temperatures inside the PEM to climb. To protect the electronics and avoid sudden thermal shutdowns, these cooling fans should be treated as a consumable service item. Under normal use, replacement every ~5 years (or sooner in hot, dusty, or high-mileage environments) is recommended as part of preventive maintenance.
Vehicle AlignmentThe Tesla Roadster puts a lot of load into a small contact patch. Short wheelbase, quick steering, heavy battery pack, and instant torque all mean the suspension geometry has to be “right” for the car to track straight and handle predictably. Over time, potholes, curb strikes, worn bushings, and even repeated hard acceleration/braking can nudge that alignment out of spec. When alignment drifts, the first place you usually see it is in the tires. On a Roadster, that often shows up as unusual or accelerated wear. A proper four-wheel vehicle alignment restores the factory camber, caster, and toe settings so all four tires share the load evenly.
2.x PEM Cooling PumpsOn 2.X Roadsters, the Coolant Pumps are central to thermal management, circulating coolant through the PEM, motor, and battery. When they weaken or fail, temperatures rise, fans run harder, and you can see power-limiting messages or thermal faults. These small electric pumps are now aging: they run hot, often for many years, and can develop internal wear, electrical issues, or leaks that introduce air and lower coolant level. Left unchecked, that extra heat stresses expensive components. Given the age of most cars, proactive coolant pump replacement is smart preventive maintenance—especially if the pumps are original, noisy, seeping coolant, or you’ve seen temperature-related alerts. New pumps restore proper flow, keep temps stable, and are cheap insurance compared to PEM, motor, or battery repairs.
1.5 PEM Cooling PumpOn 1.5 Roadsters, the Coolant Pump is a DC brush-motor unit that circulate coolant through the PEM, motor, and battery. They’re essential to keeping temperatures under control; when flow drops, heat goes up, and the car will start protecting itself with power-limiting and thermal faults. Because they’re brush motors, they wear in predictable ways over time – Brush and commutator wear – arcing and dust buildup can make the pump noisy, intermittent, or dead – Bearing wear – extra noise, vibration, and reduced flow. Aging seals – small leaks and air pockets that reduce cooling efficiency. Most original 1.5 pumps are now well past their expected 5 year service life. If yours are still original, noisy, seeping coolant, or you’ve seen temperature-related alerts, proactive replacement is smart preventive maintenance. New pumps restore flow, stabilize PEM/motor/battery temps, and are cheap insurance compared to major power-electronics or pack repairs.
Gruber Motor Company is an independent Electric Vehicle Service Center specializing in Tesla vehicles. Our facility combines traditional automotive service bays with electronics and software engineering labs, built specifically for EV diagnostics, repair, and preventive maintenance.
