repeat HVAC or thermal management system failures

[persiansamurai]

I’m posting my experience to see whether other owners have had repeat HVAC or thermal management system failures on their R1T and what long-term outcomes have been.

My vehicle first experienced HVAC failure in March 2025 at approximately 21,000 miles due to a clogged drain that was not properly draining. Since then, the same integrated HVAC/thermal management system has failed multiple times despite major warranty repairs:
• July 2025: Full HVAC / thermal management system replacement
• August 2025: System failure again requiring resealing
• October 2025: Second full HVAC / thermal management system replacement

Each of these repairs required extended service center time and resulted in significant loss of use. As many of you know, the HVAC system in this vehicle is not just for cabin comfort — it is integrated into battery thermal regulation, motor cooling, and defrost/defog safety systems. Despite these repeated major repairs, my vehicle has not demonstrated a durable long-term fix.

I pursued resolution through BBB Auto Line and have now also filed a complaint with the North Carolina Attorney General’s Office. I am currently seeking a permanent resolution after multiple failed repair attempts.

I’m posting here strictly to understand:
• Whether other owners have experienced repeat HVAC / thermal system failures
• Whether anyone has obtained a vehicle replacement or permanent fix
• Any insights on long-term reliability after full system replacement

I’m happy to share additional factual repair details if helpful. I appreciate any experiences others are willing to share.

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[technerd]

I had a critical battery warning leaving me stranded out of state, was apparently due to leaking from the HVAC system, I assume a clogged drain. They replaced the entire HVAC system with the "upgraded" one in September. I had to bring it back in within a few weeks due to shoddy and incomplete work from the original fix, but nothing new so far. Sure hope it was isolated, but I guess time will tell.

 

[Rivan]

I had almost the same experience with an R1S. After the first HVAC failure, they said it was an isolated issue, but it happened again within four months. After the third repair, I requested a full replacement under warranty. It’s frustrating, especially since the system directly affects battery cooling and overall performance.

Were you able to get a replacement ?

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