Pyro Fuse Replacements
Restore high-voltage safety disconnect protection after a blown pyro fuse, with correct diagnostics and OEM-level fitting procedures.
Pyro fuse failure (high-voltage safety disconnect)
A pyro fuse (pyrotechnic disconnect) is a high-voltage safety device designed to isolate the traction battery during a crash event, detected isolation fault, or other safety trigger. When it fires, the vehicle may not start, may show “HV system off / service required” warnings, or may refuse to charge.
Our pyro fuse replacement service focuses on confirming the root cause of the disconnect, replacing the correct component(s) safely, and validating the high-voltage system is returned to service without introducing new faults. Where relevant, we also check for the underlying trigger (e.g., crash data, isolation issues, or battery pack damage) so the same condition does not immediately recur.
Selection of Covered Vehicles - Pyro Fuse Replacements
View a selection of vehicles that have a Pyro Fuse Replacement solution
BMW
- BMW (all models) 2014-present
- BMW i4, i5, i7 and iX 2022-present
Mini
- Mini (all models) 2017-present
Porsche
- Porsche Taycan 2020-2024
Seat
- Seat/Cupra (all BEV) 2021-2024
Škoda
- Škoda (all BEV) 2021-2024
Tesla
- Tesla Model S (2012–present)
- Tesla Model X (2015–present)
- Tesla Model Y (2019–present)
- Tesla Model 3 (2017–present)
Volkswagen
- Volkswagen ID3 2021-2024
- Volkswagen ID4 2021-2024
- Volkswagen ID5 2021-2024
Can't find your vehicle?
The vehicles listed are a selection of Pyro Fuse Replacements. Please contact us if your vehicle is not listed.
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Case Studies
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Common Symptoms
HV system offline / vehicle will not ready
The vehicle will not go into drive/ready mode, often accompanied by high-voltage system shutdown messages.
Charge rejected or charging stops immediately
The vehicle may refuse AC/DC charging, or stop soon after starting, because the pack is still isolated.
Crash / restraint system history and HV isolation triggered
Following an accident (or crash event logged), the HV system may be disabled as a safety response.
Isolation fault warnings
The vehicle may report isolation faults or HV safety faults, indicating a potential underlying issue that must be addressed before (or alongside) pyro fuse replacement.
Vehicles Affected
- EVs and PHEVs with battery pack-level pyrotechnic disconnects
- Vehicles with crash-event HV isolation strategies
- Battery packs with serviceable pyro fuse assemblies (varies by manufacturer and platform)
What's Included?
Safety-first assessment and confirmation
We confirm the pyro fuse state and identify any related HV safety conditions (where accessible) before committing to replacement.
Correct component identification
We identify the appropriate pyro fuse / disconnect assembly for the vehicle and pack variant (spec depends on model, year, and battery configuration).
Replacement and HV system re-commissioning
We carry out the replacement following safe isolation procedures and re-commission the HV system where applicable.
Validation and reporting
We validate outcomes (e.g., ability to ready, charge acceptance, and any relevant HV safety checks) and provide a clear summary of what was done and what was found.
All work is backed by a 12-month warranty covering both parts and labour, giving you peace of mind and confidence in the quality of our service.
"10/10 Service! Thanks to the Kev and the team, I was able to get my VW ID3 back on the road after it had been in an accident. They went far and beyond with all the support they provided to the project. They should be your first thought when it comes to EV battery repairs"