2025-11-21

Off Road Lightbar (Remove and Replace)

Code de correction 61010002 1.20 REMARQUE : À moins d’indications explicites contraires dans la procédure, le code de correction et le temps forfaitaire ci-dessus représentent tout le travail à être fait pour cette procédure, notamment les procédures connexes. N’appliquez pas plusieurs codes de correction à la fois, à moins qu’il vous soit explicitement indiqué de le faire. REMARQUE : Consultez Temps forfaitaires pour en apprendre plus à propos des temps forfaitaires et de leur création. Vous pouvez transmettre par courriel vos commentaires relatifs aux valeurs des temps forfaitaires à ServiceManualFeedback@tesla.com. REMARQUE : Consultez Protection individuelle pour vous assurer de porter l’équipement de protection individuelle adéquat lorsque vous effectuez la procédure ci-dessous. REMARQUE : Voir Précautions ergonomiques pour consulter les pratiques de travail sécuritaires et saines.

1145158-00-A - Sac de ballast, 25 livres
1706381-00-A - Pistolet thermique sans fil
1060908-00-A - Fer à souder sans fil à allumage automatique et trousse d'outils de chauffage
Pinces à couper diagonales
DEL de lampe de poche
1082502-00-A - Coussin gonflable
1061177-00-C - Trousse de réparation de faisceau de câbles
Pinces à bec effilé
Tourne-écrou 1/4 po, 6 po x 10 mm, magnétique, profond
1115191-00-A - Petit pic à prise souple, embout à 90 degrés, 6 po
1115421-00-B - Outil de coupe en plastique
Rouleau presseur
1082497-00-A - Couteau à lame rétractable
Ciseaux
1064740-00-A - Grattoir, lame de rasoir
Petit tournevis à tête plate
1636784-00-A - Fil carré
Escabeau
1078806-00-A - Poignées en T
1080601-00-A - Jeu de racloirs à ailettes WK6 BTB

PT1500 - Ruban double face Acrylic Plus 3M
1076300-00-A - Promoteur d'adhérence
Ruban en feutre
Lingettes imbibées d’alcool isopropylique (IPA)
1937354-00-A - Barre lumineuse hors route, Cybertruck
1042541-00-A - Ruban adhésif de peintre, 1,5 po x 60 verges, bleu
Remarque
Ces numéros de pièce étaient en vigueur au moment de la publication. Utilisez les révisions indiquées ou ultérieures, à moins d’indications contraires énoncées dans le manuel des pièces.

2025-11-13: Added lightbar LH/RH body bracket R&I steps and updated the adhesion process with double-sided tape direction.
2025-10-01: Added additional images of BETASEAL 43533 primer and BETAPRIME 5504G for clarity.
2025-05-30: Added caution to further specify how to avoid using BETASEAL 43533 on the windshield.
2025-05-20: Updated the BETASEAL 43533 primer minimum dry time note to include the maximum dry time limit (110 hours).
2025-05-07: Added caution to BETASEAL 43533 primer application step.
2025-04-30: Updated general vehicle access steps; Open/close all the doors and open/close all the windows.
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.
2025-02-12: 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.

Avertissement

Cette procédure est une PREMIÈRE VERSION. Bien qu'elle ait été validée, des avertissements et des mises en garde pourraient manquer. Respectez les exigences de sécurité et faites preuve d’une extrême prudence lorsque vous travaillez sur ou près des systèmes et des composants haute tension.

Avertissement

Les composants électroniques du Cybertruck sont alimentés par une architecture moyenne tension » ou « MT » de 48 V conçue pour améliorer l'efficacité. L'entretien des composants MT nécessite des connaissances et des soins supplémentaires afin d'éviter tout dommage corporel ou au véhicule. Lisez et comprenez les précautions relatives à la MT dans Précautions en électricité et assurez-vous que tous les cours de formation requis liés à la MT ont été suivis, le cas échéant.

Avertissement

La ou les vidéos comprises dans cette procédure ont pour seul objectif de vous présenter un aperçu supplémentaire. Suivez toutes les étapes énumérées dans la procédure pour éviter d'endommager les composants et de subir des blessures personnelles.

Retirer

Remarque

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 all the doors and open all the windows.
Disconnect Mid Voltage (MV) power. See Disconnect MV Power (Modify).
Release the clips (x4) that attach the front end of the RH roof applique to the vehicle.
TIp
Nous recommandons l’utilisation des outils suivants :

1115421-00-B - Outil de coupe en plastique
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
Nous recommandons l’utilisation des outils suivants :

1082502-00-A - Coussin gonflable
Remove the RH B-pillar applique. See Applique - B-Pillar - 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.
Avertissement
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.
TIp
Nous recommandons l’utilisation des outils suivants :

Ruban en feutre
Release the clip that attaches the off road lightbar harness connector to the vehicle body, and then disconnect the connector from the B-pillar.
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.
TIp
Nous recommandons l’utilisation des outils suivants :

1115421-00-B - Outil de coupe en plastique
Remove the RH body bracket and aluminum end cap from the off road lightbar.
1. Remove the bolts (x2) that attach the RH body bracket to the off road lightbar.
  TIp
  Nous recommandons l’utilisation des outils suivants :
  
  Rallonge électrique de 4 po
  
  Clé à cliquet à tête flexible/clé dynamométrique à tête flexible
  
  Douille Torx T20
2. Remove the bolt that attaches the RH body bracket to the roof of the vehicle, and then remove the bracket from the vehicle.
  TIp
  Nous recommandons l’utilisation des outils suivants :
  
  Rallonge électrique de 4 po
  
  Clé à cliquet à tête flexible/clé dynamométrique à tête flexible
  
  Douille Torx T30
3. Release the tab that attaches the RH aluminum end cap to the off road lightbar, and then remove the cap from the vehicle.
Release the clips (x4) that attach the front end of the LH roof applique to the vehicle.
TIp
Nous recommandons l’utilisation des outils suivants :

1115421-00-B - Outil de coupe en plastique
Place the inflatable airbag under the LH roof applique, and then inflate the airbag as required to partially release the applique from the vehicle.
TIp
Nous recommandons l’utilisation des outils suivants :

1082502-00-A - Coussin gonflable
Remove the LH body bracket and aluminum end cap from the off road lightbar.
1. Remove the bolts (x2) that attach the LH body bracket to the off road lightbar.
  TIp
  Nous recommandons l’utilisation des outils suivants :
  
  Rallonge électrique de 4 po
  
  Clé à cliquet à tête flexible/clé dynamométrique à tête flexible
  
  Douille Torx T20
2. Remove the bolt that attaches the LH body bracket to the roof of the vehicle, and then remove the bracket from the vehicle.
  TIp
  Nous recommandons l’utilisation des outils suivants :
  
  Rallonge électrique de 4 po
  
  Clé à cliquet à tête flexible/clé dynamométrique à tête flexible
  
  Douille Torx T30
3. Release the tab that attaches the LH aluminum end cap to the off road lightbar, and then remove the cap from the vehicle.
Prepare the T-handles (x2) and square wire kit as required.
Remarque
Cut the desired length of wire and then secure the wire onto the T-handles.
TIp
Nous recommandons l’utilisation des outils suivants :

Pinces à couper diagonales

Pinces à bec effilé

1636784-00-A - Fil carré

1078806-00-A - Poignées en T
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.

ATTENTION
Do not damage the windshield or the lightbar harness during removal.

Remarque
Newer versions of the off road lightbar come equipped with double-sided tape pre-installed.

Remarque
The lightbar may be adhered to the windshield with urethane or double-sided tape.

Figure 1. Urethane adhesive shown for reference

Figure 2. Double-sided tape shown for reference
If present, carefully remove all urethane from the upper exterior portion of the windshield.
ATTENTION
Do not damage the windshield during urethane removal.

Remarque
Cut the urethane flush with windshield surface.
TIp
Nous recommandons l’utilisation des outils suivants :

1064740-00-A - Grattoir, lame de rasoir

1080601-00-A - Jeu de racloirs à ailettes WK6 BTB
If present, carefully remove all double-sided tape residue from the upper exterior portion of the windshield.
ATTENTION
Do not damage the windshield during double-sided tape removal.
TIp
Nous recommandons l’utilisation des outils suivants :

1064740-00-A - Grattoir, lame de rasoir

1080601-00-A - Jeu de racloirs à ailettes WK6 BTB

Remplacer

Use IPA wipes to clean the upper exterior portion of the windshield.

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

ATTENTION
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.

Remarque
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 windshield after the tape is applied, and then place the lightbar onto the roof of the vehicle.

Remarque
Make sure that the lightbar is properly aligned on the windshield.
Prepare the off road lightbar.
1. Use IPA wipes to clean the entire lightbar mating surface.
  
  Remarque
  Allow 1 minute of dry time.
2. Apply adhesive promoter to the lightbar on the entire outer path on the lightbar.
  Remarque
  Newer versions of the off road lightbar come equipped with double-sided tape pre-installed.
  
  Remarque
  All bonding surfaces must be free of impurities (dirt, dust, water, oil, grease, release agent or similar contaminants).
  
  Remarque
  Allow the adhesive promoter to completely dry before proceeding to the next step.
  TIp
  Nous recommandons l’utilisation des outils suivants :
  
  1076300-00-A - Promoteur d'adhérence
3. If not already installed, apply double-sided tape across the full length of the off road lightbar on both sides of the lightbar.
  Remarque
  The double-sided tape must be applied on both sides of the lightbar. Do not cover the center hole of the lightbar with tape, as shown.
  
  Remarque
  Use a pressure roller to help adhere the double-sided tape to the off road lightbar.
  
  Remarque
  Newer versions of the off road lightbar come equipped with double-sided tape pre-installed.
  
  Remarque
  If the double-sided tape is already installed, remove the backing paper to expose the adhesive surface of the tape.
  TIp
  Nous recommandons l’utilisation des outils suivants :
  
  PT1500 - Ruban double face Acrylic Plus 3M
  
  Rouleau presseur
  
  Ciseaux
  Figure 3. Lightbar center hole; Do not cover with tape
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 double-sided tape onto the windshield.
Carefully place the ballast bags (x2) evenly across the off road lightbar to aid with double-sided tape adhesion. The ballast bags must be left in place for 1 minute.
Remarque
Make sure that the ballast bags are positioned properly and the lightbar is securely taped to the windshield to prevent the lightbar from sliding down the windshield.
TIp
Nous recommandons l’utilisation des outils suivants :

1145158-00-A - Sac de ballast, 25 livres
After 1 minute has passed, carefully remove the ballast bags (x2) from the off road lightbar.
Install the LH body bracket and aluminum end cap.
1. Release the tabs (x6) that attach the off road lightbar LH end cap cover to the lightbar, and then remove the end cap cover from the vehicle.
2. Insert the tab on the LH aluminum end cap into the off road lightbar, and then install the end cap on the lightbar.
3. Position the LH body bracket on the vehicle, and then install the bolts (x2) that attach the body bracket to the lightbar.
  2.5 Nm (1.8 lbs-ft)
  TIp
  Nous recommandons l’utilisation des outils suivants :
  
  Rallonge électrique de 4 po
  
  Clé à cliquet à tête flexible/clé dynamométrique à tête flexible
  
  Clé à cliquet/Clé dynamométrique
  
  Douille Torx T20
4. Install the bolt that attaches the LH body bracket to the roof of the vehicle.
  7 Nm (5.2 lbs-ft)
  TIp
  Nous recommandons l’utilisation des outils suivants :
  
  Rallonge électrique de 4 po
  
  Clé à cliquet à tête flexible/clé dynamométrique à tête flexible
  
  Clé à cliquet/Clé dynamométrique
  
  Douille Torx T30
Deflate and remove the inflatable airbag from the LH roof applique.
Install the tabs (x4) that attach the front end of the LH roof applique to the vehicle.
Install the RH body bracket and aluminum end cap.
1. Release the tabs (x6) that attach the off road lightbar RH end cap cover to the lightbar, and then remove the end cap cover from the vehicle.
2. Insert the tab on the RH aluminum end cap into the off road lightbar, and then install the end cap on the lightbar.
3. Position the RH body bracket on the vehicle, and then install the bolts (x2) that attach the body bracket to the lightbar.
  2.5 Nm (1.8 lbs-ft)
  TIp
  Nous recommandons l’utilisation des outils suivants :
  
  Rallonge électrique de 4 po
  
  Clé à cliquet à tête flexible/clé dynamométrique à tête flexible
  
  Clé à cliquet/Clé dynamométrique
  
  Douille Torx T20
4. Install the bolt that attaches the RH body bracket to the roof of the vehicle.
  7 Nm (5.2 lbs-ft)
  TIp
  Nous recommandons l’utilisation des outils suivants :
  
  Rallonge électrique de 4 po
  
  Clé à cliquet à tête flexible/clé dynamométrique à tête flexible
  
  Clé à cliquet/Clé dynamométrique
  
  Douille Torx T30
Use IPA wipes to clean the off road lightbar and the windshield as required.

Remarque
Allow 1 minute of dry time.
If the off road lightbar jumper harness is present, perform the Off Road Lightbar Jumper Harness Soldering section of this procedure, and then continue to the next step.
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.

ATTENTION
Make sure that the harness is adequately supported or restrained to prevent future damage.
Position the off road lightbar harness connector on the B-pillar, and then install the clip that attaches the connector to the vehicle body.
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.

ATTENTION
Make sure that the off road lightbar harness does not pinch.
Install the RH B-pillar applique. See Applique - B-Pillar - LH (Remove and Install).
Connect MV power. See Disconnect MV Power (Modify).
Raise all the windows and close all the doors.
Refer to CD-24-90-001 for Cybertruck off road lightbar harness connection instructions.

Avertissement
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 4. Roof accessory jumper harness connector; Tesla employees are not permitted to complete this connection

Off Road Lightbar Jumper Harness Soldering

Remarque

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.

Prepare the soldering and splicing tools and consumables for the following steps as required.
Remarque
Allow 1 minute of dry time.
TIp
Nous recommandons l’utilisation des outils suivants :

1060908-00-A - Fer à souder sans fil à allumage automatique et trousse d'outils de chauffage

1061177-00-C - Trousse de réparation de faisceau de câbles
Prepare the off road lightbar jumper and heat shrink tubes (x6) for installation.

Remarque
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).
  
  Remarque
  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).

ATTENTION
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).

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

ATTENTION
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).

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

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

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

ATTENTION
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.
  
  Remarque
  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.
  
  ATTENTION
  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 8.
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.

ATTENTION
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.

ATTENTION
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.

Avertissement
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).

ATTENTION
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.

ATTENTION
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 6 through 15 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 into the vehicle 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.

ATTENTION
Make sure that the harness is adequately supported or restrained to prevent future damage.