02/12/2024 15:07:47

Off Road Lightbar (Mount on Windshield and Solder Only) (Retrofit)

Correction code 61010006 0.84 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.

2024-12-02: Added caution to the RH roof applique reinstallation step to avoid pinching the lightbar harness.
2024-11-01: Updated procedure title and added image of the roof accessory jumper harness connector for clarity.
2024-10-17: Added harness schematic designators for the roof top accessory and lightbar B-pillar connectors.
2024-10-07: Updated lightbar mounting procedure, urethane bead size perimeter thickness, and b-pillar connector direction to align with latest validation.
2024-07-25: Added link to CD-24-90-001.
2024-07-02: Added step for installing blackout film tape on lightbar.
2024-05-15: Updated procedure with new urethane application method.

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.

Retrofit

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.

Open the front doors and lower the front windows.
Disconnect Mid Voltage (MV) power. See Disconnect MV Power.
Remove the RH B-pillar applique. See Exterior Trim Fittings - B-Pillar Applique - LH (Remove and Install).
Release the red locking tab and then disconnect the roof accessory jumper harness (connector X0965F) from the off road lightbar harness (connector X0965M).
Use felt tape to secure the roof accessory jumper harness connector to the vehicle.
Warning
Tesla employees are not permitted to connect or assist with the 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.
Tip: Use of the following tool(s) is recommended:
- Felt Tape
Install the RH B-pillar applique. See Exterior Trim Fittings - B-Pillar Applique - LH (Remove and Install).
Use IPA wipes to clean the upper exterior portion of the windshield.

Note
Allow 1 minute of dry time.
If not already installed, remove the protective cover from the provided blackout film tape, and then install the blackout film tape on the lightbar.

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.

Note
Position the lightbar on a level surface while applying the tape. Make sure the tape fully covers the front side of the lightbar.
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 vehicle after the tape is applied.

Note
Make sure that the lightbar is properly aligned on the windshield.
Apply primer to the windshield on the entire urethane path on the windshield.
Note
Allow 1 minute of dry time.
Tip: Use of the following tool(s) is recommended:
- 1053830-00-A - BETAPRIME 5504G
Prepare the off road lightbar.
1. Use IPA wipes to clean the entire lightbar mating surface.
  
  Note
  Allow 1 minute of dry time.
2. Apply primer to the lightbar on the entire urethane path on the lightbar.
  Note
  Make sure that the lightbar mating surface is clean before applying primer onto the lightbar.
  
  Note
  Allow 1 minute of dry time.
  Tip: Use of the following tool(s) is recommended:
  - Primer, BETASEAL 43533
3. Install the net pads (x6) on the off road lightbar.
  Note
  Place the net pads evenly along the center of the lightbar.
  
  Note
  The net pads will aid in setting the gap between the lightbar and the windshield.
  Tip: Use of the following tool(s) is recommended:
  - Net Pad, 40X8X1.5 - 1043739-00-B
Prepare the caulking gun and urethane.
Note
Opening must be 5 mm wide and 6 mm tall.
Tip: Use of the following tool(s) is recommended:
- Retractable Blade Knife - 1082497-00-A
- Tool, Caulking & Adhesive Gun, M18 - 1080593-00-A
Apply the urethane following the primer path on the off road lightbar.

Note
Verify that the outer urethane beads are married to avoid NVH issues.
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.
Use a 2 mm body gap and flush gauge to set the off road lightbar evenly across the windshield.
Tip: Use of the following tool(s) is recommended:
- Body Gap and Flush Gauge (2 mm) - 1588903-00-A
Apply masking tape across the off road lightbar to secure the lightbar to the windshield. Allow the urethane to fully dry.
Tip: Use of the following tool(s) is recommended:
- Masking Tape - 1042541-00-A
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.
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.
Tip: Use of the following tool(s) is recommended:
- Ballast Bag, 25 LB - 1145158-00-A
After one hour has passed, carefully remove the ballast bags (x2) from the off road lightbar.
Remove all masking tape from the off road lightbar and the windshield, and then remove the protective tape from the upper surface of the lightbar.

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.
Use IPA wipes to clean the off road lightbar and the windshield as required.

Note
Allow 1 minute of dry time.
Release the clips (x4) that attach the front end of the RH roof applique to the vehicle.
Tip: Use of the following tool(s) is recommended:
- Plastic Trim Tool
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.
Tip: Use of the following tool(s) is recommended:
- Inflatable Air Bag - 1082502-00-A
Route the off road lightbar harness into the vehicle.

CAUTION
Make sure that the harness does not pinch.
Use a pair of scissors to carefully cut and remove the electrical and harness tape from the roof accessory jumper harness.

CAUTION
Do not cut or damage the jumper harness.
Use a small flat head screwdriver to release the grommet that attaches the roof accessory jumper harness to the vehicle.
Tip: Use of the following tool(s) is recommended:
- Small Flat Head Screwdriver
Rotate the roof accessory jumper harness clockwise towards the front of the vehicle.
Reinstall the grommet that attaches the roof accessory jumper harness to the vehicle.
Prepare the soldering and splicing tools and consumables for the following steps as required.
Tip: Use of the following tool(s) is recommended:
- Cordless, Self-Igniting Soldering Iron and Heat Tool Kit - 1060908-00-A
- Wire Harness Repair Kit - 1061177-00-A
Prepare the off road lightbar jumper and heat shrink tubes (x6) for installation.

Note
The off road lightbar jumper may come with a green or blue Local Interconnect Network (LIN) wire. Make note of this for the jumper connection steps later in this procedure.
1. Remove and discard the pre-cut insulation from the off road lightbar jumper wire ends (x6).
  
  Note
  The off road lightbar jumper sleeve is shown removed from the jumper for the remainder of this procedure for clarity purposes. Do not remove the jumper sleeve from the jumper at any point.
Remove and discard the protective caps (x6) from the roof accessory jumper harness wire ends (x3) and the off road lightbar harness wire ends (x3).

CAUTION
Failure to properly disconnect MV power prior to splicing into the MV power circuit can result in damage to the vehicle or the MV battery. Tesla is not responsible for any damage to the vehicle or MV battery.
Use a wire stripper to strip approximately ½ inch of insulation from the roof accessory jumper harness wire ends (x3) and the off road lightbar harness ends (x3).

Warning
Wear appropriate Personal Protective Equipment (PPE) including cut-resistant gloves and safety glasses when performing this step.

CAUTION
Do not cut or damage the harness wires while removing the insulation.
Prepare to install the off road lightbar jumper wires (x3) to the roof accessory jumper harness according to the wiring configuration diagram.
Carefully wrap the roof accessory jumper harness wire ends (x3) around the off road lightbar jumper wire ends (x3).

CAUTION
Splicing the off-road lightbar harness into the jumper harness incorrectly may damage the lightbar.

Note
Make sure that the wire ends are properly secured and wrapped evenly.
Put on cut-resistant mechanic’s gloves or other heat-resistant gloves.

Warning
Always read and understand the soldering iron operator’s manual before using it to solder or shrink heat shrink tubing.

CAUTION
Do not use the soldering iron in an area where surrounding surfaces, materials, or components could be damaged by hot air.
Use the wire harness repair kit to solder the roof accessory jumper harness and the off road lightbar jumper connections (x3).
1. Make sure that the wires are free of dirt and grease.
2. Install the soldering tip on the soldering iron.
3. Turn on the soldering iron and allow it to fully warm up.
4. Clean the tip of the soldering iron with a damp sponge.
  
  Note
  Replace the tip if it does not have a shiny appearance, or if solder does not melt on the tip when it is fully warmed up.
5. Apply a small amount of solder to the tip of the soldering iron.
6. Use the soldering iron to apply solder onto the wires (x3).
7. Stop applying solder when it evenly covers the outer surfaces of the wires.
8. Remove the soldering iron from the wires before the solder wicks into the wire insulation or the soldering iron overheats the insulation.
9. Hold the solder connections still while returning the soldering iron to a safe location.
10. Turn off the soldering iron and allow it to cool down.
  
  CAUTION
  Heating the soldering iron unnecessarily degrades the surface of the soldering tip.
Inspect the solder connections. If the solder is in a spherical shape, or did not evenly flow across the wires, the soldering iron was not hot enough, repeat step 35.
Slide the heat shrink tubes (x3) over the roof accessory jumper harness and the off road lightbar jumper connections (x3), aligning the center of the tubes with the center of the connections.

CAUTION
Do not skip this step. The procedure will have to be repeated if the wires are spliced without installing the heat shrink tubes on the wires.

CAUTION
Make sure the soldered wires have cooled down before sliding the heat shrink tubes over the jumper connections.
Once the soldering tip has cooled, remove it from the soldering iron and install the flame tip and deflector tip.

Warning
Make sure that the soldering tip has cooled completely before removing it.
While continuously moving the soldering iron or heat gun in a left-to-right motion, apply heat over the length and diameter of the heat shrink tubes (x3) to affix the tubes to the wires connections (x3).

CAUTION
Avoid overheating any specific section of the heat shrink tubes or wiring. Any discoloration of the wiring insulation indicates overheating.
Turn off the soldering iron and return it to a safe location.
Allow the heat shrink tubes (x3) and wires to cool.
Inspect the heat shrink tubes (x3) to make sure that the tubes are fully sealed and bonded to the wire insulation.
Prepare to install the off road lightbar jumper wires (x3) to the off road lightbar harness according to the wiring configuration diagram.
Slide the remaining heat shrink tubes (x3) over the off road lightbar jumper wires (x3) and move them aside.

CAUTION
Do not skip this step. The procedure will have to be repeated if the wires are spliced without installing the heat shrink tubes on the wires.
Repeat steps 33 through 42 for the remaining off road lightbar jumper wire ends (x3) and the off road lightbar harness wire ends (x3) as required.
Wrap the entire off road lightbar harness and splice areas with electrical tape.
Wrap the entire off road lightbar harness and splice areas with new harness tape.
Route the off road lightbar harness as required to prevent pinching or rubbing when the RH roof applique is reinstalled, and then use harness tape to secure the harness to the vehicle.

CAUTION
Make sure that the harness is adequately supported or restrained to prevent future damage.
Deflate and remove the inflatable airbag from the RH roof applique.
Install the tabs (x4) that attach the front end of the RH roof applique to the vehicle.

CAUTION
Make sure that the off road lightbar harness does not pinch.
Connect MV power. See Disconnect MV Power.
Raise the front windows and close the front doors.
Refer to CD-24-90-001 for Cybertruck off road lightbar harness connection instructions.

Warning
Tesla employees are not permitted to connect or assist with the 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