23/07/2024 17:35:11

Tonneau - Flat Cassette Assembly - LH (Remove and Replace)

Correction code NA FRT 2.30 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.

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 the tonneau slats. See Slat System - Tonneau (Remove and Install).
Open all 4 doors

Note
Push pillar door triggers to release
Lower all 4 windows
Move LH front seat forward
Move RH front seat forward
Open powered front trunk

Note
Via exterior switch or UI
Power down vehicle via UI

Note
Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
Remove rear underhood apron

Note
9x clips
Unlock fireman's loop connector and disconnect, Slide eCPA to left on the MV battery connector then lift lever to release

Note
2x connectors, Unlock fireman's loop connector and disconnect, Release eCPA by pushing down to unlock and slide red locking tab to left, Wait 2 minutes for electrical circuits to discharge before disconnecting modules
Remove front header trim

Note
19x clips, 1x magnet, 1x connector, 1x harness clip
Remove LH mid A-pillar trim

Note
2x clips, 2x tabs, Release tabs, Slightly bend live hinge and release clips
Remove LH IP quarter panel

Note
3x clips, 5x tabs, 2x datums
Remove LH upper A-pillar panel

Note
8x clips, 1x tether clip, 1x harness clip, 1x connector, 1x bolt, 10mm, 6 Nm, Pull inwards to release, Depress tabs on either side of tether clip to release
Remove rear header trim

Note
12x clips, 3x datums
Remove LH lower C-pillar trim

Note
3x clips, 7x tabs, 4x datums, Starting at door sill pull upward then forward to release, Leave trim attached to seat belt
Open LH coat hook

Note
Press to release
Release LH coat hook bolt cover

Note
2x tabs
Remove LH coat hook bolt

Note
1x bolt, T20, 2.5 Nm
Remove LH cantrail trim panel

Note
5x clips, 1x connector, 3x bolts, T30, 6 Nm, Release clips then allow cantrail to hang from tethers for access to fasteners
Disconnect headliner harness from LH rear maplight

Note
1x connector
Remove LH cantrail trim panel

Note
5x clips, 1x connector, 3x bolts, T30, 6 Nm, Release clips then allow cantrail to hang from tethers for access to fasteners
Remove LH 2nd row shoulder cover

Note
7x clips, 1x datum
Remove 2nd row seatback LH outboard bolster

Note
5x clips, 2x datums, Release from bottom
Remove LH C-pillar upper trim

Note
5x clips, 3x tabs
Remove interior fasteners securing lower tonneau assembly

Note
2x bolts, 13mm, 20 Nm
Remove fastener covers from bed floor assembly

Note
6x covers
Remove bed floor assembly

Note
10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance
Open bed cargo tub lid
Remove cargo tub struts from cargo lid

Note
2x strut clips
Remove bed cargo tub lid

Note
4x bolts, 10mm, 5 Nm, Recommend assistance
Remove LH bed closeout panel

Note
6x clips, 1x tab, Release LH tailgate cable by disengaging lock spring from bolt and sliding cable eyelet off to allow removal of bed closeout panel from vehicle
Remove LH lower bed side wall

Note
1x bolt, 15mm, 46 Nm, 2x bolts, T45, 36 Nm, 4x bolts, 10mm, 11 Nm, 2x nuts, 10mm, 7 Nm, 4x clips, 1x fastener cover, 1x connector, Release locking tabs, Disconnect bed outlet connectors from bed side wall and ground strap, 1x bolt, 10mm, 10 Nm, 2x connectors, Release locking tabs, Slide lock to release, Recommend assistance
Remove RH bed closeout panel

Note
6x clips, 1x tab, Release RH tailgate cable by disengaging lock spring from bolt and sliding cable eyelet off in order to remove bed closeout panel from vehicle
Remove RH bed side wall

Note
1x bolt, 15mm, 46 Nm, 2x bolts, T40, 36 Nm, 4x bolts, 10mm, 11 Nm, 2x nuts, 10mm, 7 Nm, 4x clips, 1x fastener cover, 1x connector, Release locking tabs
Remove false wall

Note
2x bolts, 15mm, 45 Nm. Recommended to use assistance to prevent scratching bed liner
Release RH tonneau NVH barrier

Note
6x bolts, 10mm, 5 Nm, 2-piece NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal, Vehicles built before September 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm
Remove RH tonneau NVH barrier

Note
Release rearward then slide over LH side NVH cover before removing upward, Vehicles built before September 2024 will have 1-piece NVH cover, Maneuver around bed wall then remove
Release LH tonneau NVH barrier

Note
5x bolts, 10mm, 5 Nm, 2-piece NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal
Remove LH tonneau NVH barrier

Note
Slide towards center, Ensure busbar clearance during removal to avoid damage to NVH material
Remove rear tonneau cover box cross supports

Note
8x screws, T25, 5 Nm
Remove front tonneau cover box cross supports

Note
8x screws, T25, 5 Nm
Remove tonneau applique

Note
2x bolts, T30, 9 Nm, Remove bolts then firmly pull upward from rear edge of applique to release rear of applique, Depress locking tab on forward mounting points to release
Remove LH backlight applique assembly

Note
2x clips, 1x adhesive strip, Cut adhesive then pry inward to release
Remove LH tonneau motor

Note
1x connector, 2x bolts, 10mm, 11 Nm
Remove lower tonneau brackets

Note
2x nuts, 13mm, 30 Nm, 1x bolts, 13mm, 30 Nm
Remove lower tonneau assembly fasteners

Note
1x nut, 10mm, 6 Nm, 1x bolt, 10mm, 6 Nm, 1x bolt, 13mm, 20 Nm
Remove LH tonneau flat cassette assembly

Note
Lift upwards to release from datum on back wall
Install LH tonneau flat cassette assembly

Note
Engage datum at back wall
Install LH tonneau flat cassette fasteners

Note
1x nut, 10mm, 6 Nm, 1x bolt, 10mm, 6 Nm, 1x bolt, 13mm, 20 Nm
Install LH lower tonneau bracket

Note
2x nuts, 13mm, 30 Nm, 1x bolts, 13mm, 30 Nm
Install LH tonneau motor

Note
1x connector, 2x bolts, 10mm, 11 Nm
Instal LH backlight applique assembly

Note
2x clips, Replace any missing or damaged clips, Install new double sided adhesive
Install tonneau applique

Note
2x bolts, T30, 9 Nm, Position over mounting points then apply downward pressure to engage front and rear attachment points, Install bolts, Ensure seal is not caught outboard of applique, Use trim tool to adjust seal position as required
Install front tonneau cover box cross supports

Note
8x screws, T25, 5 Nm
Secure rear tonneau cover box cross supports

Note
8x screws, T25, 5 Nm, Supports install in the same direction of the fasteners
Install LH tonneau NVH barrier

Note
2-piece NVH assembly order of operations requires LH side to be secured first to allow busbar clearance for RH side installation, Ensure busbar clearance during install to avoid damage to NVH material
Secure LH tonneau NVH barrier

Note
5x bolts, 10mm, 5 Nm
Install RH tonneau NVH barrier

Note
2-piece NVH assembly order of operations requires LH side to be secured first to allow busbar clearance for RH side installation, Vehicles built before September 2024 will have 1-piece NVH cover, Maneuver around bed wall then position
Secure RH tonneau NVH barrier

Note
6x bolts, 10mm, 5 Nm, Vehicles built before September 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm
Install false wall

Note
2x bolts, 15mm, 45 Nm. Recommended to use assistance to prevent scratching bed liner
Install RH bed side wall

Note
1x bolt, 15mm, 46 Nm, 2x bolts, T40, 36 Nm, 4x bolts, 10mm, 11 Nm, 2x nuts, 10mm, 7 Nm, 4x clips, 1x fastener cover, 1x connector, Recommend assistance
Install RH bed closeout panel

Note
6x clips, 1x tab, Release RH tailgate cable to install bed closeout panel from vehicle
Install LH lower bed side wall

Note
1x bolt, 15mm, 46 Nm, 2x bolts, 13mm, 36 Nm, 4x bolts, 10mm, 11 Nm, 2x nuts, 10mm, 7 Nm, 4x clips, 1x fastener cover, 1x connector, Secure locking tabs, Connect bed outlet connectors onto bed side wall and ground strap, 1x bolt, 10mm, 10 Nm, 2x connectors, Secure locking tabs, Slide lock to secure, Recommend assistance
Install LH bed closeout panel

Note
6x clips, 1x tab, Secure LH tailgate cable once closeout installed
Install bed cargo tub lid

Note
4x bolts, 10mm, 6 Nm, Snug bolts, Torque will be done at later step, Position bed cargo tub lid onto vehicle, Install bolts securing bed cargo tub lid onto hinges, Recommend assistance
Install cargo tub struts onto cargo lid

Note
2x strut clips
Close bed cargo tub lid
Install bed floor assembly

Note
10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance
Install fastener covers onto bed floor assembly

Note
6x covers
Install interior fasteners securing lower tonneau assembly

Note
2x bolts, 13mm, 20 Nm
Install LH C-pillar upper panel

Note
5x clips, 3x tabs
Install 2nd row seatback LH outboard bolster

Note
5x clips, 2x datums, Replace any missing or damaged clips
Install LH 2nd row shoulder cover

Note
7x clips, 1x datum
Install LH cantrail panel

Note
5x clips, 1x connector, 3x bolts, T30, 6 Nm, Secure tethers then secure clips
Install LH coat hook bolt

Note
1x bolt, T20, 2.5 Nm
Secure LH coat hook bolt cover

Note
2x tabs
Close LH coat hook

Note
Press to secure
Secure LH lower C-pillar trim

Note
1x clip, 1x datum
Install LH upper A-pillar panel

Note
8x clips, 1x tether clip, 1x edge clip, 1x connector, 1x bolt, 10mm, 6 Nm, Ensure tethers are correctly oriented, Replace any missing or damaged clips
Install LH mid A-pillar trim

Note
2x clips, 2x tabs, Replace any missing or damaged clips
Install rear header trim

Note
12x clips, 3x datums, Replace any missing or damaged clips
Install front header trim

Note
19x clips, 1x magnet, 1x connector, 1x harness clip
Move LH front seat to original position
Move RH front seat to original position
Raise all 4 windows

Note
Verify switch is operating as expected
Close all 4 doors
Install the tonneau slats. See Slat System - Tonneau (Remove and Install).

Cybertruck Service Manual

Tonneau - Flat Cassette Assembly - LH (Remove and Replace)

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