2025-03-24

Glass - Roof - Fixed (Remove and Replace)

10205002 1.02 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.

  • 2025-03-24: 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.
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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.
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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.

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
    Informational PurposesAn informational icon, calling your attention
    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
    Informational PurposesAn informational icon, calling your attention
    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
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, discard per local regulations
  15. Remove old urethane from body
    Informational PurposesAn informational icon, calling your attention
    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. Attach suction cups to roof glass
  21. Position roof glass onto vehicle for dry fit
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  22. 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
  23. Remove roof glass and set it upside-down onto stand
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  24. Remove protective tape from vehicle body
  25. Clean glass mating surfaces with isopropyl alcohol
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time
  26. 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
  27. Prepare caulking gun and urethane
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    Note
    Opening must be 12mm wide and 19mm tall, 8mm wide and 13mm tall
  28. Apply urethane to body
    Informational PurposesAn informational icon, calling your attention
    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.
  29. Place roof glass onto vehicle but do not set yet
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance. Align datums on LH side of vehicle at front and rear corners of glass to body
  30. 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
  31. Press glass onto body once in position
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    Note
    Use sandbags for the front if needed
  32. 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/
  33. Remove suction cups from roof glass
  34. Remove protective tape from headliner
  35. Close liftgate
  36. Raise all four windows
  37. Close all four doors