30/07/2024 14:25:00

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

Correction code 61010006 FRT 0.18 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.

  • 2024-07-25: 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.
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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.

Retrofit

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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.
  3. Use IPA wipes to clean the upper exterior portion of the windshield.
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    Note
    Allow 1 minute of dry time.
  4. If not already installed, remove the protective cover from the provided blackout film tape and then install the blackout film tape on the lightbar.
    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.
    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.
  5. 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.
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    Note
    Make sure that the lightbar is properly aligned on the windshield.
  6. Apply primer to the windshield on the entire urethane path on the windshield.
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    Note
    Allow 1 minute of dry time.
    Tip: Use of the following tool(s) is recommended:
    • 1053830-00-A - BETAPRIME 5504G
  7. Prepare the off road lightbar.
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    Note
    Make sure that the lightbar mating surface is clean before applying primer onto the 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.
      Informational PurposesAn informational icon, calling your attention
      Note
      Allow 1 minute of dry time.
      Tip: Use of the following tool(s) is recommended:
      • Primer, BETASEAL 43533
  8. Prepare the caulking gun and urethane.
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    Note
    Opening must be 7 mm wide and 12 mm tall.
    Tip: Use of the following tool(s) is recommended:
    • Retractable Blade Knife
    • Tool, Caulking & Adhesive Gun, M18
  9. Apply the urethane following the primer path on the off road lightbar.
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    Note
    Verify that the outer urethane beads are married to avoid NVH issues.
  10. 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.
  11. Use a 3 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
  12. Apply masking tape across the off road lightbar to secure the lightbar to the windshield. Allow the urethane to fully dry.
  13. Release the clips (x4) that attach the front of the RH roof applique to the vehicle, and then use an inflatable air bag to keep the applique separated from the body.
    Tip: Use of the following tool(s) is recommended:
    • Inflatable Air Bag
    • Plastic Trim Tool
  14. Route the off road lightbar harness into the vehicle.
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    Note
    Make sure that the harness does not pinch.
  15. Remove the inflatable air bag, and then secure the clips (x4) that attach the front portion of the RH roof applique to the vehicle.
  16. 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 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.
  17. Use IPA wipes to clean the off road lightbar and the windshield as required.
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    Note
    Allow 1 minute of dry time.
  18. Connect MV power. See Disconnect MV Power.
  19. Raise the front windows and close the front doors.
  20. Refer to CD-24-90-001 for Cybertruck off road lightbar harness connection instructions.
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    Note
    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. You are responsible for using these instructions to complete the lightbar harness connection yourself.