2026-10-14

Glass - Roof - Fixed (Remove and Replace)

10205002 1.02 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

  • 2026-10-14: Updated procedure to replace T-handles with Spider Cutting Tool.
  • 2025-03-24: Updated procedure so that the side rails and headliner are not released.
  • 2024-12-10: Added new caution about Pre-Installation Glass Inspection service requirements.
  • 2023-08-28: Updated the installation steps.
CAUTION
For Europe only: Only technicians who have been trained in working with diisocyanates and have completed all required certification courses are permitted to perform procedures using urethane and other products containing diisocyanates. Proper personal protective equipment (PPE) must be worn when working with products containing diisocyanates.
CAUTION
New glass components (windshield, roof, door, and fixed glass) must be inspected before installation to meet Tesla’s internal standards of quality. Perform the inspection described in Pre-Installation Glass Inspection before beginning this procedure.

Remove

  1. Open all four doors and lower all four windows.
  2. Measure and record gaps from fixed roof glass to windshield, body sides, and liftgate glass.
    Note
    Measurements will be used during installation of new glass.
  3. Separate the front and the rear datums from the roof glass by sliding the equalizer blade up against the datums and carefully separating the adhesive from the roof glass using a rubber mallet.
    Note
    One datum at front center, one datum at LH rear corner. You may not be able to see the datum clearly, but you can feel for it using the blade.
  4. Prepare WRD Spider 3 glass removal kit
  5. Loop the cutting string through the wire starter.
  6. Insert the wire starter through the roof glass urethane at the rear corner.
    Note
    Take caution when doing this. Use the protective shield. Avoid damage to painted surfaces.
  7. Remove the string from the wire starter using an angled pick, and pull enough string through to wrap around the circumference of the fixed glass.
    Note
    Use plier to help pull the string if needed.
  8. Remove the wire starter tool from the vehicle.
  9. Pull the nylon string through the hole in the urethane, leaving enough string to wrap around the perimeter of the glass with both ends inside the vehicle.
    Note
    Do not pull the string through completely.
  10. Route the nylon string around the glass perimeter, lifting the seals to place the string under the seals.
    CAUTION
    Do not damage the front windshield and liftgate seals.
    Note
    If the roof glass is being replaced, the roof glass seals can be off.
  11. Secure the nylon string onto the wire starter and push the wire starter into the vehicle. Using a pick, pull enough nylon string into the interior to secure onto the spider cutting tools, then cut the string.
  12. Secure one end of the nylon string to the spider cutting tool: follow the instructions on the spider tool, 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 in the proper direction, the cutting tool will be damaged.
    Warning
    If a drill is used to wind up the string on the spider tool, the drill clutch must be set to 1 to avoid risk of injury.
  13. Secure one end of the nylon string to the anchor.
    Note
    Keep the anchor at the correct cutting angle.
  14. Secure the glass removal anchor to the interior of the roof glass.
    Note
    Keep the anchor at the correct cutting angle.
  15. Secure the spider cutting tool to the interior side of the fixed roof glass assembly, noting the orientation of the cutting line and ensuring the line wraps over the large pulley and holds at a 90-degree angle.
  16. Secure the angle driver to the electric drill.
    Warning
    if a drill is used to wind up string on spider tool, drill clutch must be set to 1 to avoid risk of injury.
  17. Cut the roof glass urethane with the spider tool (2 x datums, 4 x roof brackets).
    1. Attach the drill with angle driver to the square drive on the spider tool.
    2. Operate the drill to drive the spider cutting tool.
    3. Apply upward pressure to the string as it cuts with the dash protector.
    4. Make sure the string goes above the datums, roof brackets, and the antenna located at the rear center.
    CAUTION
    If the string gets caught under a bracket, it will break. Pull the string backwards to release it from under the metal roof bracket. Also try swapping the position of the anchor and cutting tool if the line is caught.
  18. Secure suction cups to roof glass at each corner.
    Note
    4x suction cup tools. Recommend assistance.
  19. Remove fixed roof glass from vehicle.
    Note
    Recommend assistance. Discard per local regulations.
  20. Remove the old urethane from body.
    Note
    Ensure residual urethane is 1 mm or less in thickness.
  21. Remove datums and any other debris from the body.
  22. Wipe body with IPA to clean the surface.
    Note
    Allow 1 minute dry time.
  23. Replace any body plugs or tape that were damaged during removal or cleaning.

Install

  1. Inspect XM antenna to make sure it is secure and the foam is not damaged.
    Note
    If damaged, please replace as needed.
  2. Attach suction cups to the roof glass.
  3. Position roof glass onto vehicle for dry fit.
    Note
    Recommend assistance.
  4. Make sure gaps are all within acceptable limits.
    Note
    If glass is too high, it may be necessary to trim or remove net pads.
  5. Remove roof glass and set it upside-down onto stand.
    Note
    Recommend assistance.
  6. Apply primer to body on urethane path and any areas that were damaged during removal.
    Note
    If vehicle is equipped with roof rack anchors, primer should go around the inside of the roof bracket. If vehicle is not equipped with roof rack brackets, primer outside the roof rack bracket mounting holes. Allow primer to dry for at least 1 minute.
  7. Prepare caulking gun and urethane.
    Note
    Opening must be 12mm wide and 19mm tall, 8mm wide and 13mm tall.
  8. Apply urethane to body.
    Note
    If equipped with roof rack anchors urethane should go around the inside of the roof rack anchor, if not urethane should go on the outside of the anchor mounting holes.
  9. Place roof glass onto vehicle but do not set yet.
    Note
    Recommend assistance. Align datums on LH side of vehicle at front and rear corners of glass to body.
  10. Position new seal at front of glass beneath windshield seal.
    Note
    A trim tool can be used to properly seat the roof glass seal under the windshield seal.
  11. Press glass onto body once in position.
    Note
    Use sandbags for the front if needed.
  12. Verify clearances with liftgate glass, windshield, and body sides are within specification.
    Note
  13. Remove suction cups from the roof glass.
  14. Close the liftgate.
  15. Raise all four windows and close all four doors.