Now over 91000 miles traveled. Two more breakdowns requiring AA recovery both due to brushes getting stuck in their holders. I am now working on replacing the 25 x 10 mm ones with 11/4 x 1/2 inch (60% larger area. This is to reduce the rapid heating of the brushes causing the brush tails to pull out. A lot of the existing size brushes failed early due to wires pulling out of the carbon block.

Traction battery charger module burnout.  

One night the battery didn't charge. After checking the fuse in the plug I followed the power back to the charger module within the large ECU. I removed the module and discovered the mains input choke had burnt out. 

The reason for the burnout is too little copper around the pad. The pads unaffected were to copper planes. To fix it I have made a direct link to the plane using the winding directly.