HVAC Assembly Unit Rebuild – 6002801

HVAC Assembly Rebuild Service – 6002801

This service covers a complete rebuild of the Tesla Roadster HVAC assembly, including both the evaporator core and the PTC electric heater. The Roadster HVAC box is a custom, low-volume part that is no longer produced, making professional rebuilding the only practical way to keep these cars heating and cooling properly. Your original unit is carefully disassembled, cleaned, repaired, re-sealed, and tested before being returned ready to re-install.

Why these fail

• Age & corrosion — Moisture and road salts attack the aluminum evaporator and hardware inside the HVAC box.
• Contaminated airflow — Dust and bio-growth build up on the fin pack and inside ducts, causing odors and reduced airflow.
• PTC heater fatigue — Thermal cycling stresses the PTC heater elements and connections, leading to weak or no cabin heat.
• Seals & foam breakdown — Original foam pads, gaskets, and drain seals deteriorate, causing rattles, air leaks, and condensation issues.
• Obsolete, custom housing — The molded HVAC enclosure and components are Roadster-specific and no longer available new from Tesla.

Our solution

• Complete disassembly — We remove the blower, evaporator, PTC heater, internal flap, actuator, sensors, and harness from the housing.
• Deep cleaning — Housing, duct passages, and components are cleaned and decontaminated to remove debris, corrosion, and odor-causing residue.
• Evaporator service — The evaporator is leak-checked; when required we replace the core, renew insulation, and fit a new TXV or seals as specified.
• PTC heater inspection — PTC elements and connections are tested under load; damaged or weak heaters are repaired or replaced when parts are available.
• New seals & hardware — Critical gaskets, foam pads, flap seals, and mounting hardware are renewed for proper airflow and drainage.
• Bench testing — Rebuilt assemblies are electrically tested, blower operation is verified, and flap/actuator motion is checked before shipment.

Service & coverage

Rebuilt HVAC assemblies are covered by Gruber Motor Company’s limited 1-year warranty against workmanship defects when installed and serviced by a qualified technician. Because housings and many internal parts are no longer manufactured, warranty coverage is limited to repair or re-work of the customer’s existing unit.