Alerts in Tesla's Service Mode will contain additional details on what triggered the alert
@Greentheonly/Twitter
Most modern cars come with access to a Controller Area Network (CAN) that lets you access information about systems in the vehicle.
It's often used to help diagnose vehicle issues and find out if a certain part may need to be replaced.
Teslas, just like other vehicles will display critical alerts or warnings on the screen based on CAN data.
The warnings can be as simple as being low on windshield wiper fluid. They could also alert you of critical issues such as airbag errors or heat pump issues.
Service Mode
For owners or shops who wish to troubleshoot or repair their vehicles, Tesla also includes a Service Mode.
Service Mode gives you access to more details about any alerts the vehicle has shown, as well as letting you reset certain systems.
Not every vehicle alert is customer-facing, meaning that some alerts only show up in Service Mode. These alerts could be temporary warnings without any customer impact, so they're of limited use to the vehicle owner, but they could be useful to a technician diagnosing an issue.
Although Service Mode displays additional details about vehicle alerts, they've also been somewhat limited.
Alerts are triggered based on certain readings from the vehicle's CAN, which provides real-time information on a slew of vehicle systems and any errors they report.
If the vehicle detects a high temperature or low voltage in a given system, it may trigger an alert. The user may see an alert such 'X system not available', although usually the reason is omitted.
In Service Mode, some additional information may be shown about a given alert, such as why it was triggered, such as due to low voltage.
However, up until now the additional information provided in the alert in Service Mode has been somewhat limited.
Alert Payload
In a recent update, Tesla has added individual CAN readings to the alert, known as the alert payload, or crack data. Instead of seeing a simple 'low voltage detected' message, technicians or DIY owners can now see the exact value of the voltage when the alert was triggered.
Twitter user @greentheonly shared this news on Twitter, showing a screenshot that shows the plethora of information that is now available to Model S and X owners. Model 3 and Model Y owners do not yet have access to this data, but it's reportedly coming soon in a future update.
Adding alert payload data to Service Mode is a significant shift, as Tesla kept this information close to the chest and encouraged owners to take their vehicles to Tesla service centers. However, with this kind of information now available, third-party electric vehicle shops will have the data to fix Teslas. Not only shops but do-it-yourself types will also have access to the same information previously available to the technical support team.
That said, it’s important to note that Tesla’s warranty can be voided “due to improper maintenance, service or repairs.” The warranty paperwork, which you should read before ever tinkering with a Tesla, or any expensive item, clearly detailed how the company “strongly recommends that you have all maintenance, service and repairs done at a Tesla Service Center or Tesla authorized repair facility in order to avoid voiding or having coverage excluded under this New Vehicle Limited Warranty.”
@greentheonly’s tweet got a lot of attention. In a follow-up tweet, the user tells readers to enter service mode, and the information can be found in the service mode menu. The tweet is accompanied by a short video showing how to get to service mode. The screenshot shows active alerts with drop-down menus that provide more details.
Reddit comments were supportive of having more information. One poster said: “After they made the service manuals free, I’ve found I can do literally whatever I’d like! I no longer need service to answer questions about parts, processes, or fixes. Just look it up in the manual!”
While another, clearly a DIYer, posted, “This pleases me. Hopefully, between this and the free service manual online, most repairs should be able to be done at home.”
But another commenter believes Tesla is still holding too much back, “Now give us gateway config tasks on the toolbox, and we'll actually be able to make meaningful changes to our car.”
Keep in mind that Service Mode is aimed at technicians and is not meant to be accessed by customers. The information displayed is not consumer friendly and will often require some vehicle knowledge to be useful.
Service mode will also disable various safety systems while in use, and it is not recommended to be accessed by customers.
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Tesla’s Cybertruck has officially earned a 5-Star Safety Rating from the NHTSA—an impressive achievement given the vehicle’s design. The achievement demonstrates Tesla’s engineering prowess. As one engineer points out, it wasn’t an easy feat.
Interestingly, the NHTSA only recently disclosed the results, despite the crash tests being completed a while ago. According to Lars Moravy, Tesla’s VP of Vehicle Engineering, the team had been aware of the 5-star rating for quite some time. While the reason for the delay remains unclear, now that the results are public, Tesla’s engineers can finally share how they achieved the rating.
Crumple Zones
Wes Morril, the Cybertruck’s Lead Engineer, wrote about the crash test video on X recently, addressing the claims that the Cybertruck doesn’t have a crumple zone. He also posted a side-by-side video (below) of the engineering analysis and the crash test itself.
Engineered Crash Safety
There’s a lot of engineering precision at play when a Cybertruck is involved in a crash. Unlike traditional crash structures that rely on crash cans and collapse points, the Cybertruck’s front gigacasting is designed to absorb and redirect impact forces in a highly controlled manner.
It all starts with the bumper beam, which crushes within the first few milliseconds of a high-speed impact. At the same time, the vehicle’s sensors rapidly analyze the crash dynamics and determine the optimal deployment of safety restraints, including airbags and seat belt pre-tensioners. These split-second actions are crucial in keeping occupants safe.
As the crash progresses, the vehicle’s structure deforms in a carefully engineered sequence. The drive unit cradle bends, directing the solid drive unit downward and out of the way, allowing the gigacasting to begin absorbing impact forces.
The casting crushes cell by cell, methodically dissipating energy in a controlled manner. This gradual deceleration reduces the g-forces transferred to occupants, making the crash much less severe. As the gigacast begins crushing, the safety restraints are deployed.
As Wes points out in his post - you can see how accurate the virtual analysis and modeling were. The video shows the simulated crash side by side with the real-life crash test and they’re almost identical. All that virtual testing helps provide feedback into the loop to design a better and safer system - one that is uniquely different than any other vehicle on the road.
All the armchair experts claimed the Cybertruck has no crumple zone and I get it, the proportions seem impossible. It was a tough one and there is a lot of engineering that went into it. Let me break it down for you:
Tesla has pioneered the use of single-piece castings for the front and rear sections of their vehicles, thanks to its innovative Gigapress process. Many automakers are now following suit, as this approach allows the crash structure to be integrated directly into the casting.
This makes the castings not only safer but also easier to manufacture in a single step, reducing costs and improving repairability. For example, replacing the entire rear frame of a Cybertruck is estimated to cost under $10,000 USD, with most of the expense coming from labor, according to estimates shared on X after high-speed rear collisions.
These insights come from Sandy Munro’s interview (posted below) with Lars Moravy, Tesla’s VP of Vehicle Engineering, highlighting how these advancements contribute to the improvements in Tesla’s latest vehicles, including the New Model Y.
However, with the new Model Y, Tesla has decided to go a different route and eliminated the front gigacast.
No Front Casting
Tesla’s factories aren’t equipped to produce both front and rear castings for the Model Y. Only Giga Texas and Giga Berlin used structural battery packs, but these were quickly phased out due to the underwhelming performance of the first-generation 4680 battery.
Tesla has gone back to building a common body across the globe, increasing part interchangeability and reducing supply chain complexity across the four factories that produce the Model Y. They’ve instead improved and reduced the number of unique parts up front to help simplify assembly and repair.
There is still potential for Tesla to switch back to using a front and rear casting - especially with their innovative unboxed assembly method. However, that will also require Tesla to begin using a structural battery pack again, which could potentially happen in the future with new battery technology.
Rear Casting Improvements
The rear casting has been completely redesigned, shedding 7 kg (15.4 lbs) and cutting machining time in half. Originally weighing around 67 kg (147 lbs), the new casting is now approximately 60 kg (132 lbs).
This 15% weight reduction improves both vehicle dynamics and range while also increasing the rear structure’s stiffness, reducing body flex during maneuvers.
Tesla leveraged its in-house fluid dynamics software to optimize the design, resulting in castings that resemble organic structures in some areas and flowing river patterns in others. Additionally, manufacturing efficiency has dramatically improved—the casting process, which originally took 180 seconds per part, has been reduced to just 75 seconds, a nearly 60% time reduction per unit.
Advancements in die-casting machines and cooling systems have allowed @Tesla to dramatically reduce cycle times and improve dimensional stability. pic.twitter.com/WB5ji67rvV
Tesla’s new casting method incorporates conformal cooling, which cools the die directly within the gigapress. Tesla has been refining the die-casting machines and collaborating with manufacturers to improve the gigapress process.
In 2023, Tesla patented a thermal control unit for the casting process. This system uses real-time temperature analysis and precise mixing of metal streams to optimize casting quality. SETI Park, which covers Tesla’s manufacturing patents on X, offers a great series for those interested in learning more.
The new system allows Tesla to control the flow of cooling liquid, precisely directing water to different parts of the die, cooling them at varying rates. This enables faster material flow and quicker cooling, improving both dimensional stability and the speed of removing the part from the press for the next stage.
With these new process improvements, Tesla now rolls out a new Model Y at Giga Berlin, Giga Texas, and Fremont every 43 seconds—an astounding achievement in auto manufacturing. Meanwhile, Giga Shanghai operates two Model Y lines, delivering a completed vehicle every 35 seconds.
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