29/08/2024 08:05:49

Fixed Glass Roof Assembly (Remove and Replace)

Correction code 1020106012 1020106011 FRT 1.74 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.

2024-03-12: Cleaned up topic.

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.

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.

Remove

Open all the doors and lower all the windows.
Open the powered frunk.
Open the tailgate.
Open the tonneau cover.
Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
Disconnect MV power. See Disconnect MV Power.
Remove the front header trim. See Headliner Trim - Front Header Trim (Remove and Install).
Remove the rear header trim. See Headliner Trim - Rear Header Trim (Remove and Install).
Remove the LH and RH mid A-pillar trims. See A-B-C Positivet Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
Remove the LH and RH upper A-pillar trims. See A-B-C Positivet Interior Trim - A-Pillar Upper Trim - LH (Remove and Install).
Remove the LH and RH cantrail trims. See Headliner Trim - Cantrail Trim - LH (Remove and Install).
Remove the LH and RH roof appliques. See Exterior Trim Fittings - Roof Applique - LH (Remove and Install).
Remove the tonneau applique. See Tonneau Applique (Remove and Install).
Remove the Telematics Control Unit (TCU) as an assembly. See Antennas and Amplifiers - TLA, Telematics Control Unit (TCU) (Remove and Install).

Note
It is not necessary to remove the TCU from the bracket.
Disconnect the LH and RH roof antenna electrical connectors.

Figure 1. LH roof antenna electrical connector

Figure 2. RH roof antenna electrical connector
Remove the mounting bosses from the roof assembly.

Note
x3 plastic bosses

Note
Cut the adhesive using the equalizer with short blade.

CAUTION
Use caution with the equalizer to avoid cracking the glass.
Cut the roof assembly interior double urethane path.

Note
Cut the urethane at the front LH and RH corners using the equalizer with short blade. This will allow easier cutting of exterior path.

CAUTION
Use caution with the equalizer to avoid cracking the glass.
Cut the roof assembly exterior rear double urethane path and datums.

Note
x2 datums

Note
Cut the urethane along the rear section of the roof assembly using the equalizer with long blade.

Note
Ensure datums are cut at both LH and RH rear corners. This will allow easier cutting of the exterior path.

CAUTION
Use caution with the equalizer to avoid cracking the glass.
Measure and record the gap and flush on the windshield and roof glass.

Note
Measure at the front of windshield. Measure from the LH and RH edge to cantrail panels at the front and rear of roof assembly.

Note
Measurements will be used during the installation of the new glass.
Prepare the WRD Spider 3 glass removal kit.
Push the cutting line through to the exterior.

Note
Secure the line to tip of starting tool. Push through at an easily accessible location on the exterior.

Note
Keep the tool flush to the glass to avoid contacting the body.
Route the cutting line around the exterior perimeter of the roof assembly.

Note
Ensure enough length is pulled through the glass.

Note
Verify the line sits underneath the glass and the seal.
Insert the end of the nylon cord through the eye of starter tool and pull it into the inside of the body.

Note
Starting tool shall be close to the glass corner as far as possible so as to obtain relatively large space for the nylon rope to pass through.
Attach the anchor point to the interior of the roof assembly and secure the line.

Note
Tie off the end of cutting line, and then thread the handle down.
Secure the interior side of the line to the spider cutting tool.

Note
Follow the instructions on the spider tool.

Note
Feed the line through the opening of the cutting tool and tie a knot to secure it in place.

CAUTION
If the spindle is not turned the proper direction, the cutting tool will be damaged.
Secure the spider cutting tool to the interior side of the fixed roof glass assembly.

Note
Note the orientation of the cutting line.

Note
Ensure the line wraps over the large pulley and holds at a 90 degree angle or greater.
Secure the angle driver to the powered drill.
Cut the remaining urethane securing the roof assembly to the body.

Note
Move the cutting tool as needed in order to keep the line close to a 90 degree angle.

Note
Use plastic guard as required to guide the cutting line.
Remove the spider cutting tool and anchor point.

Note
Release the suction cups.
Secure the suction cups (x4) to the roof glass.
Remove the fixed roof glass from the body.

Note
Recommend assistance.
Remove the suction cups (x4) from the old roof glass.
Remove the old urethane from the body, and then wipe the body with Isopropyl Alcohol (IPA) wipes to clean the surface.

Note
Allow 1 minute dry time.

Install

Attach the suction cups (x4) to the new roof assembly.

Note
Place the suction cups to allow easy lifting of the glass.
Apply primer to the vehicle body on the urethane path.

Note
Apply primer to any exposed metal.

Note
Allow primer to dry for two minutes before installing the roof assembly.

Note
Wipe away any primer drips with IPA wipes.
Prepare the caulking gun and urethane.

Note
Opening must be 12 mm wide and 18 mm tall.
Apply urethane to the roof assembly.

Note
3 tubes of urethane are required.

Note
Follow the primer path.

Note
Ensure overlap occurs at the rear center of glass.

Note
Smooth out any gaps with IPA wipes.
Install the roof assembly onto the vehicle.

Note
Recommend assistance.

Note
Align the datums at the rear of the roof assembly.
Push the glass downwards.

Note
Firmly push downwards around the perimeter of the glass.

Note
Height datums will not allow the glass to become under-flush.
Install the tonneau applique. See Tonneau Applique (Remove and Install).
Verify and adjust the gap and flush between the windshield and the roof glass.

Note
Measure at the windshield and between the roof edge to cantrail panel, and adjust if necessary.

Note
Refer to measurements taken during removal.

Note
Refer to CVIS for latest specifications.
Install the LH and RH roof appliques. See Exterior Trim Fittings - Roof Applique - LH (Remove and Install).
Apply tape to secure the roof glass.

Note
Tape to the windshield to ensure the roof glass will not shift.
Remove the suction cups (x4) from the roof.
Reposition the windshield seal, if necessary.

Note
Spray glass cleaner to lubricate the seal, if necessary.
Connect the LH and RH roof antenna electrical connectors.

Figure 3. LH roof antenna electrical connector

Figure 4. RH roof antenna electrical connector
Install the Telematics Control Unit (TCU). See Antennas and Amplifiers - TLA, Telematics Control Unit (TCU) (Remove and Install).
Install the LH and RH cantrail trims. See Headliner Trim - Cantrail Trim - LH (Remove and Install).
Install the LH and RH upper A-pillar trims. See A-B-C Positivet Interior Trim - A-Pillar Upper Trim - LH (Remove and Install).
Install the LH and RH mid A-pillar trims. See A-B-C Positivet Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
Install the rear header trim. See Headliner Trim - Rear Header Trim (Remove and Install).
Install the front header trim. See Headliner Trim - Front Header Trim (Remove and Install).
Reconnect MV power. See Disconnect MV Power.
Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
Close the powered frunk.
Close the tonneau cover.
Close the tailgate.
Raise all the windows and close all the doors.