The reason: The rear chassis of the electric SUV, the so-called rear end, is no longer assembled from 70 individual parts, but consists of a single structural casting, a so-called giga-casting.
Currently, the production of the Model Y is being converted in the plants in the USA, in China and in Grünheide in Brandenburg. The problem with the switch to large castings is that individual parts damaged after accidents can no longer be replaced at low cost. If the rear end were to be severely damaged, it would have to be replaced completely, according to the report. This would be tantamount to a total economic loss.
Otherwise, the manufacturer would have to submit a repair concept that specifies how these parts can be repaired using processes that can be controlled in repair workshops."
Welding aluminum castings is notoriously difficult and they tend to crack when deformed. Tesla has not yet presented a repair concept.
Since only a few Model Y with cast-iron rear ends have been on the road and involved in accidents so far, the industry expects that there will be no data on the level of repair costs until next year. By then, the popular mid-size SUV could already be upgraded.
