2025-02-27

Off Road Lightbar (Remove and Install)

Correction code 61010001 1.20 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 1145158-00-A - Ballast Bag, 25 lb.
  • 1588903-00-A - Body Gap & Flush Gauge, Model Y
  • Diagonal Cutters
  • Felt Tape
  • Flashlight LED
  • 1082502-00-A - Inflatable Air Bag
  • Isopropyl Alcohol (IPA) Wipes
  • Needle Nose Pliers
  • Nutsetter 1/4 in. Dr. 6 in. x 10mm Magnetic Deep
  • 1115191-00-A - Pick Miniature Soft Grip 90 Degree Tip 6 in.
  • 1115421-00-B - Plastic Trim Tool
  • 1082497-00-A - Retractable Blade Knife
  • Scissors
  • 1064740-00-A - Scraper, Razor Blade
  • Small Flat Head Screwdriver
  • 1636784-00-A - Square Wire
  • Step Stool
  • 1042541-00-A - Tape, Painters, 1.5 in. x 60 yards, Blue
  • 1080593-00-A - Tool, Caulking & Adhesive Gun, M18
  • 1078806-00-A - T-Handles
  • 1080601-00-A - WK6 BTB Winged Scraper Set
  • 1053830-00-A - BETAPRIME 5504G
  • 1048645-00-A - BETASEAL Express/Express+
  • 1043739-00-B - Net Pad, 40 x 8 x 1.5
  • 1011953-01-B - Primer, BETASEAL 43533 - 150 ml
    Informational PurposesAn informational icon, calling your attention
    Note
    These part numbers were current at the time of publication. Use the revisions listed or later, unless otherwise specified in the Parts Catalog.
  • 2025-02-25: Added tools and consumables list at the top of the procedure for clarification. Added a new note to the windshield primer application step. Updated BETAPRIME 5504G minimum drying time to align with supplier requirements. Removed duplicate note about general cleaning requirements.
  • 2025-02-19: Added lightbar installation video for clarification.
  • 2025-02-13: Updated the cautions, notes, and part number for the lightbar primer application. Replaced soldering direction with B-pillar connector steps.
  • 2025-02-03: Added urethane description and part number.
  • 2024-12-02: Added caution to the RH roof applique reinstallation step to avoid pinching the lightbar harness.
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Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
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Warning
Cybertruck electronics are powered by a 48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing MV components requires extra knowledge and care in order to avoid personal and/or vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any required MV-related training courses have been completed, as applicable.
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Warning
The video(s) included in this procedure are meant as an overview for supplemental purposes only. Follow all of the steps listed in the procedure to avoid damage to components and/or personal injury.

Remove

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Note
The Tesla Lightbar for Cybertruck is designed only for off road use. Tesla by law cannot install the lightbar electronics and configure the vehicle for lightbar control.
  1. Open the front doors and lower the front windows.
  2. Disconnect Mid Voltage (MV) power. See Disconnect MV Power (Modify).
  3. Release the clips (x4) that attach the front end of the RH roof applique to the vehicle.
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    TIp
    Use of the following tool(s) is recommended:
    • 1115421-00-B - Plastic Trim Tool
  4. Place the inflatable airbag under the RH roof applique, and then inflate the airbag as required to partially release the applique from the vehicle for access to the roof accessory jumper harness.
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    TIp
    Use of the following tool(s) is recommended:
    • 1082502-00-A - Inflatable Air Bag
  5. Remove the RH B-pillar applique. See Exterior Trim Fittings - B-Pillar Applique - LH (Remove and Install).
  6. Release the red locking tab and then disconnect the roof accessory jumper harness connector (X0965F) from the off road lightbar harness connector (X0965M).
  7. Use felt tape to secure the roof accessory jumper harness connector to the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Tesla employees are not permitted to connect or assist with the RH B-pillar connection of the Cybertruck off road lightbar harness to the roof accessory jumper harness connector. Only the customer or a third-party entity is permitted to complete the lightbar harness connection.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Felt Tape
  8. Release the clip that attaches the off road lightbar harness connector to the vehicle body, and then disconnect the connector from the B-pillar.
  9. Remove the roof accessory grommet plug from the vehicle, and then carefully remove the off road lightbar harness from the B-pillar through the roof accessory grommet opening.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 1115421-00-B - Plastic Trim Tool
  10. Prepare the T-handles (x2) and square wire kit as required.
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    Note
    Cut the desired length of wire and then secure the wire onto the T-handles.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Diagonal Cutters
    • Needle Nose Pliers
    • 1636784-00-A - Square Wire
    • 1078806-00-A - T-Handles
  11. With assistance, use the T-handles (x2) and square wire kit to carefully remove the off road lightbar from the windshield, and then remove the lightbar from the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage the windshield or the lightbar harness during removal.
  12. Carefully remove all urethane from the upper exterior portion of the windshield.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage the windshield during urethane removal.
    Informational PurposesAn informational icon, calling your attention
    Note
    Cut the urethane flush with windshield surface.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 1064740-00-A - Scraper, Razor Blade
    • 1080601-00-A - WK6 BTB Winged Scraper Set

Install

  1. Use IPA wipes to clean the upper exterior portion of the windshield.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute of dry time.
  2. If not already installed, remove the protective cover from the blackout film tape, and then install the blackout film tape on the lightbar.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The blackout film tape must be installed on the lightbar prior to delivering the vehicle to the customer. Only the customer or a third-party entity is permitted to remove the blackout film tape.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the lightbar on a level surface while applying the tape. Make sure the tape fully covers the front side of the lightbar.
  3. Dry fit the off road lightbar on the windshield, and then apply masking tape along the lower portion of the lightbar to create a perimeter across the windshield. Remove the lightbar from the windshield after the tape is applied, and then place the lightbar onto the roof of the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the lightbar is properly aligned on the windshield.
  4. Apply primer to the windshield on the entire urethane path on the windshield.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 2 minutes of dry time.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 1053830-00-A - BETAPRIME 5504G
  5. Prepare the off road lightbar.
    1. Use IPA wipes to clean the entire lightbar mating surface.
      Informational PurposesAn informational icon, calling your attention
      Note
      Allow 1 minute of dry time.
    2. Apply primer to the lightbar on the entire urethane path on the lightbar.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not use BETAPRIME 5504G on the lightbar mating surface.
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      Note
      The BETASEAL 43533 primer must be shaken for 10 minutes before application.
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      Note
      All bonding surfaces must be free of impurities (dirt, dust, water, oil, grease, release agent or similar contaminants).
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      Note
      Ambient room temperature for lightbar primer application must be between 50-95 degrees Fahrenheit. The lightbar primer must be applied indoors.
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      Note
      BETASEAL 43533 primer must be used on the lightbar mating surface to allow proper adhesion.
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      Note
      Once the BETASEAL 43533 primer container is opened, the expiration life is 24 hours. If the primer container is opened at all, do not use the primer and assume that the primer is expired (unless the opened container date is explicitly noted on the container and within the 24 hour expiration life timeframe).
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      Note
      Allow the primer to dry for at least 30 minutes to ensure proper adhesion.
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      TIp
      Use of the following tool(s) is recommended:
      • 1011953-01-B - Primer, BETASEAL 43533 - 150 ml
    3. Install the net pads (x6) on the off road lightbar.
      Informational PurposesAn informational icon, calling your attention
      Note
      Place the net pads evenly along the center of the lightbar.
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      Note
      The net pads will aid in setting the gap between the lightbar and the windshield.
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      TIp
      Use of the following tool(s) is recommended:
      • 1043739-00-B - Net Pad, 40 x 8 x 1.5
  6. Prepare the caulking gun and urethane.
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    Note
    Opening must be 5 mm wide and 6 mm tall.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 1048645-00-A - BETASEAL Express/Express+
    • 1082497-00-A - Retractable Blade Knife
    • 1080593-00-A - Tool, Caulking & Adhesive Gun, M18
  7. Apply the urethane following the primer path on the off road lightbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify that the outer urethane beads are married to avoid NVH issues.
    Informational PurposesAn informational icon, calling your attention
    Note
    The lightbar must be installed on the windshield immediately after the urethane is applied on the lightbar.
  8. With assistance, align the upper portion of the lightbar with the upper exterior portion of the windshield, position the lightbar evenly on the windshield, and then press down on the lightbar to fully adhere the urethane onto the windshield.
  9. Use a 2 mm body gap and flush gauge to set the off road lightbar evenly across the windshield.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 1588903-00-A - Body Gap & Flush Gauge, Model Y
  10. Apply masking tape across the off road lightbar to secure the lightbar to the windshield. Allow the urethane to fully dry.
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    TIp
    Use of the following tool(s) is recommended:
    • 1042541-00-A - Tape, Painters, 1.5 in. x 60 yards, Blue
  11. Carefully place the ballast bags (x2) evenly across the off road lightbar to aid with urethane adhesion. The ballast bags must be left in place for one hour before the vehicle can be released to the customer.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the ballast bags are positioned properly and the lightbar is securely taped to the roof and windshield to prevent the lightbar from sliding down the windshield.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 1145158-00-A - Ballast Bag, 25 lb.
  12. After one hour has passed, carefully remove the ballast bags (x2) from the off road lightbar.
  13. Remove all masking tape from the off road lightbar and the windshield. If installed, remove the protective tape from the upper surface of the lightbar.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Tesla employees are not permitted to remove the blackout film tape from the lightbar. Do not remove the blackout film tape from the front side of the lightbar.
  14. Use IPA wipes to clean the off road lightbar and the windshield as required.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute of dry time.
  15. Route the off road lightbar harness into the vehicle through the roof accessory grommet opening as required to prevent pinching or rubbing when the RH roof applique is reinstalled, and then install the roof accessory grommet plug on the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the harness is adequately supported or restrained to prevent future damage.
  16. Position the off road lightbar harness connector on the B-pillar, and then install the clip that attaches the connector to the vehicle body.
  17. Deflate and remove the inflatable airbag from the RH roof applique.
  18. Install the tabs (x4) that attach the front end of the RH roof applique to the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the off road lightbar harness does not pinch.
  19. Install the RH B-pillar applique. See Exterior Trim Fittings - B-Pillar Applique - LH (Remove and Install).
  20. Connect MV power. See Disconnect MV Power (Modify).
  21. Raise the front windows and close the front doors.
  22. Refer to CD-24-90-001 for Cybertruck off road lightbar harness connection instructions.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Tesla employees are not permitted to connect or assist with the RH B-pillar connection of the Cybertruck off road lightbar harness to the roof accessory jumper harness connector. Only the customer or a third-party entity is permitted to complete the lightbar harness connection.
    Figure 1. Roof accessory jumper harness connector; Tesla employees are not permitted to complete this connection