03/07/2024 16:03:47

Roof Assembly

Repair Information

  • This procedure is for the solid roof. Use Service Manual procedure 24102002 for the panoramic roof assembly or Service Manual procedure 10205002 for the glass roof.
  • This procedure covers both Remove and Replace and Remove and Install of the roof assembly.
  • This repair can be performed with the windshield, liftgate, and headliner in place.
  • Refer to Approved Chemicals for a list of approved foam products and structural adhesives.
  • Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.
  • This procedure can be completed without using a frame bench.

Parts List

Quantity Description Image / Notes
1 COMPLETE ROOF ASSEMBLY (Roof Assembly)
4 BUTYL FOIL, 300X150, 2MM THICK
2 SEAL, OUTER TRIM, BASE ROOF (Outer Trim Seal)
7 BASE ROOF FRONT SPACER
4 BASE ROOF REAR SPACER
1 Dow BETAPRIME™ 5504G primer
As needed Dow BETASEAL™ Express Urethane Sealant Source locally; not available from Tesla.

These part numbers were current at the time of publication. Use the revisions listed or later, unless otherwise specified in the Parts Manual.

Repair Procedure

  1. Remove the original component.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Avoid cutting into underlying components when cutting the urethane sealant.
    Informational PurposesAn informational icon, calling your attention
    Note
    If performing a Remove and Install of the roof assembly, a special tool is used: the Equalizer Python Urethane Wire Removal System (or an equivalent tool). The technician using this tool must be trained and certified to use the tool.
    Cut the urethane sealant to release the Roof Assembly from the:
    1. Rear Header
      Informational PurposesAn informational icon, calling your attention
      Note
      There is a small portion in the middle of the Rear Header that is slightly higher than the rest of the Rear Header. Take care when cutting the urethane sealant in that area to avoid cutting into the raised portion of the Rear Header.
    2. Front Header
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      The Front Header is slightly higher in the middle than on the sides. Take care when cutting the urethane sealant to avoid cutting into the Front Header.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      When removing the front portion of the Roof Assembly, make sure not to damage the windshield.
    3. Roof Rails
  2. Remove the remaining urethane sealant from the vehicle in preparation for new urethane sealant during installation.
  3. Install the butyl foil pads on the new Roof Assembly in the arrangement shown (butyl foil pads shown in light grey).
  4. Install the outer trim seals.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The outer trim seals must be installed properly before applying urethane sealant.
  5. Peel the backing off of the roof spacers and attach them to the Roof Assembly in the indicated locations.
    • Front spacers (x7)
    • Rear spacers (x4)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the spacers do not protrude from the edges of the Roof Assembly or they will be visible after installation.
  6. Put the Roof Assembly into position and check the fit (reposition or trim the roof spacers as necessary to achieve a proper fit).
  7. Apply primer to any exposed surfaces and any painted areas of the mating surfaces on the vehicle and the Roof Assembly.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Urethane sealant will not bond properly to painted surfaces. Prime all painted surfaces in the bond path before applying urethane sealant.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Follow the primer manufacturer's instructions for drying time. Do not continue until the primer has dried sufficiently.
  8. Apply a bead of urethane sealant to the vehicle on top of the original urethane path.
    Informational PurposesAn informational icon, calling your attention
    Note
    Modify the butyl patches and roof spacers as necessary (by repositioning or trimming them) to achieve a proper fit and match the original configuration.
  9. With an assistant, put the Roof Assembly on the vehicle and adjust it so that the gaps are even on all sides.
  10. Press down on the perimeter of the Roof Assembly to seal the urethane sealant.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage the surrounding components when pressing down on the Roof Assembly.
  11. Apply suitable tape or weights (such as sand bags) to hold the roof in place while the urethane sealant cures.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not drive the vehicle until the urethane sealant has cured. Refer to the manufacturer's documentation for the safe drive-away time.
  12. Perform any necessary post-repair operations.