2025-03-26

Glass - Roof - Fixed (Remove and Install)

Correction code 10205001 1.56 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 proper PPE is worn when performing the below procedure.

  • 2025-03-26: Updated procedure so that the side rails and headliner are not released.
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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.

Procedure

  1. Open all four doors
  2. Lower all four windows
  3. Apply tape to the vehicle exterior
    Informational PurposesAn informational icon, calling your attention
    Note
    Cover the side rails and front corners of the liftgate
  4. Measure and record gaps from fixed roof glass to windshield, body sides, and liftgate glass
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    Note
    Measurements will be used during installation of new glass
  5. Open liftgate
  6. Apply masking tape to protect the headliner
  7. Cut length of square wire to use with T-handles
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    Note
    Make sure there's adequate wire
  8. Insert tool through roof glass urethane at rear corner
  9. Attach square wire and pull tool back through into vehicle
  10. Insert square wire into one T-handle
  11. Attach second T-handle
  12. Using T-handles, cut urethane securing roof glass to body
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Use caution near XM antenna, roof rack blocks, and bolts for brackets near B-pillars, Protect headliners by using a guard to prevent the wire from damaging the headliner
  13. Secure suction cups to roof glass at each corner
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    Note
    4x suction cup tools, Recommend assistance
  14. Remove fixed roof glass from vehicle
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    Note
    Recommend assistance, discard per local regulations
  15. Remove old urethane from body
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    Note
    Ensure residual urethane is 1 mm or less in thickness
  16. Remove datums and any other debris from body
  17. Wipe body with IPA to clean surface
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    Note
    Allow 1 minute dry time
  18. Replace any body plugs or tape that were damaged during removal or cleaning
  19. Inspect XM antenna to make sure it is secure and the foam is not damaged
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    Note
    If damaged, please replace as needed.
  20. Inspect roof glass for any damage that is not reworkable
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    Note
    Replace roof glass if there is any damage that can not be rectified. Damages include: cracked glass, chipped or mutilated glass edges
  21. Remove urethane bead and seals from roof glass
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    Note
    Retain the flat perimeter bead as much as possible, which creates a flat raised surface on 3 sides for installation, Remove any rough uneven surfaces and all of the manually applied urethane bead
  22. Remove damaged datums from roof glass
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    Note
    2x datums
  23. Remove all net pads from roof glass
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    Note
    6x net pads
  24. Clean double sided tape residue
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    Note
    If needed, an eraser wheel can be used
  25. Clean all mating surfaces with IPA
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    Note
    Allow 1 minute dry time
  26. Install front datum to roof glass
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    Note
    1x datum
  27. Install rear locator pin to roof glass
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    Note
    1x datum, Align within etched marking on glass
  28. Install net pads to roof glass
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    Note
    6x net pads, Align within etched markings on glass, Large nets pads on rear edge of glass, Smaller net pads on front edge of glass
  29. Install front seal to roof glass
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    Note
    Align seal to etching at corner of glass, Peel away adhesive backing and apply seal a few inches at a time along the edge of the glass
  30. Install LH side seal to roof glass
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    Note
    Pull tab for adhesive strip faces rear edge of glass, Front side of seal will have a longer gap to the first spacer than the rear, Align seal to etching at corner of glass, Peel away adhesive backing and apply seal a few inches at a time along the edge of the glass
  31. Install RH side seal to roof glass
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    Note
    Pull tab for adhesive strip faces rear edge of glass, Front side of seal will have a longer gap to the first spacer than the rear, Align seal to etching at corner of glass, Peel away adhesive backing and apply seal a few inches at a time along the edge of the glass
  32. Install rear seal to roof glass
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    Note
    Align seal to etching at corner of glass, Peel away adhesive backing and apply seal a few inches at a time along the edge of the glass
  33. Attach suction cups to roof glass
  34. Position roof glass onto vehicle for dry fit
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    Note
    Recommend assistance
  35. Make sure gaps are all within acceptable limits
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    Note
    If glass is too high, it may be necessary to trim or remove net pads
  36. Remove roof glass and set it upside-down onto stand
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    Note
    Recommend assistance
  37. Remove protective tape from vehicle body
  38. Clean glass mating surfaces with isopropyl alcohol
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    Note
    Allow 1 minute dry time
  39. Apply primer to body on urethane path and any areas that were damaged during removal
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    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
  40. Apply primer to roof glass along urethane path
  41. Prepare caulking gun and urethane
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    Note
    Opening must be 12mm wide and 19mm tall, 8mm wide and 13mm tall
  42. Apply urethane to body
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    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.
  43. Place roof glass onto vehicle but do not set yet
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    Note
    Recommend assistance. Align datums on LH side of vehicle at front and rear corners of glass to body
  44. Position new seal at front of glass beneath windshield seal
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    Note
    A trim tool can be used to properly seat the roof glass seal under the windshield seal
  45. Press glass onto body once in position
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    Note
    Use sandbags for the front if needed
  46. Verify clearances with liftgate glass, windshield, and body sides are within CVIS specification
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    Note
    Adjust if necessary, CVIS => https://quality.prd2.dt.teslamotors.com/
  47. Remove suction cups from roof glass
  48. Remove protective tape from headliner
  49. Close liftgate
  50. Raise all four windows
  51. Close all four doors