Lower Rear Door Repair Guidelines

Provides guidelines for use when repairing the lower section of a Model X rear door.

Minor dents and paint chips can be repaired on Model X lower rear doors. Use the guidelines below when performing repairs.

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Note
After completing any repair to the lower rear door, visually inspect the ultrasonic sensor area. Make sure that all butyl is firmly attached to the interior of the lower rear door skin, and that the ultrasonic sensor carrier is completely attached to the lower rear door skin.

Sheet Metal Repairs

  • Do not perform any type of dent repair within a 30 cm (11 in) diameter area of the ultrasonic sensor (the area circled in red).
  • Body filler is not allowed in the ultrasonic sensor area.
  • Body filler in repair areas outside of the ultrasonic sensor area must not exceed 2 mm (1/16 in) in depth.
  • Remove any butyl patches on the back side of a dent when using an aluminum dent puller to weld on aluminum pull tabs or studs. This ensures that the key or stud can attach properly to the aluminum panel being straightened.
  • If any butyl patch is removed for the repair, replace it with a new butyl patch.
  • Add a butyl patch to the backside of any new repair. Make sure that the patch is 5 cm (2 in) larger than the repair area.
  • Do not drill holes in any component to allow access for paintless dent repair (PDR) tools.
  • Avoid excessive vibration and heat during the repair. Excessive vibration and heat might affect the ability for the butyl patch and ultrasonic sensor to remain properly attached to the lower rear door skin.

Paint Repairs

  • Paint thickness must not exceed 300 microns (12 mils) in the ultrasonic sensor area. (300 microns is approximately 1 factory coat and 1 recoat).
  • If additional paint would cause the paint thickness to exceed 300 microns (12 mils) in the ultrasonic sensor area, remove all paint in the area to expose the bare aluminum and prepare the door based on the paint manufacturer’s recommendations.
  • Do not paint the interior of the door skin.

Ultrasonic Sensor Replacement

The ultrasonic sensor is a one-time use part and must be replaced if it is removed from the door (refer to Service Manual procedure 11334202).

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CAUTION
A force gauge must be used to install a new ultrasonic sensor. Failure to use a force gauge results in incorrect ultrasonic sensor installation and might affect sensor performance.

If the ultrasonic sensor carrier must be replaced, refer to Service Manual procedure 11334702 for instructions on installing the ultrasonic sensor carrier.