2024-12-10

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.

  • 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.

Remove

  1. Remove the LH mid A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  2. Remove the LH IP end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  3. Remove the LH upper A-pillar trim. See Trim - A-Pillar - Upper - LH (Remove and Replace).
  4. Remove the driver sun visor. See Sun Visor - LH (Remove and Replace).
  5. Repeat step 1 through step 4 for the RH side of the vehicle.
  6. Remove the rear view mirror. See Mirror - Rear View (Remove and Replace).
  7. Remove the upper quad camera cover. See Upper Cover - Rear View Mirror (Remove and Replace).
  8. Remove the upper B-pillar trim. See Trim - B-Pillar - Upper - LH (Remove and Replace).
  9. Push open the LH rear coat hook.
  10. Pry open to release the tabs (x2) that attach the LH rear coat hook screw cover.
  11. Remove the screw that attaches the LH rear coat hook to the headliner.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx T25 socket
  12. Repeat step 8 through step 11 for the RH side of the vehicle.
  13. Fold the LH 2nd row seat to the down position.
  14. Remove the rear trunk parcel shelf. See Parcel Shelf - Rear Trunk (Remove and Replace).
  15. Release the clips (x7) that attach the LH upper C-pillar trim, and then move the trim aside. Repeat this step for the RH trim.
  16. Remove the bolts (x2) that attach the rear of the headliner to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are located on the LH and RH sides of the headliner.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  17. Release the clips (x18) and hooks (x2) that attach the headliner to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Headliner will be supported by tethers (x8) when released; push upward and inward to release hooks on the coat hook assemblies from the body.
  18. Close the liftgate.
  19. Apply masking tape to cover the side rails and front corners of the liftgate.
  20. Measure and record gaps from the 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.
  21. Open the liftgate.
  22. Apply masking tape to protect the headliner.
  23. Prepare a pair of T-handles with square wire 6 feet long.
  24. Insert the tool through the fixed roof glass urethane at the rear corner.
  25. Attach the square wire and pull the tool back through into the vehicle.
  26. Insert the square wire into one T-handle.
  27. Attach a second T-handle.
  28. With assistance, use the T-handles to cut the urethane securing the fixed roof glass to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution near XM antenna, roof rack blocks, and bolts for brackets near B-pillars.
  29. With assistance, attach suction cups to the roof glass at each corner.
  30. With assistance, remove the fixed roof glass from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard per local regulations.
  31. Use a scraper to remove the old urethane from the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure residual urethane is 1 mm or less in thickness.
  32. Remove the datums and any other debris from the body.
  33. Use IPA wipes to clean the body surface.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute of dry time.
  34. Replace any body plugs or tape that were damaged during removal or cleaning.
  35. Inspect the XM antenna to make sure it is secure and the foam is not damaged.
    Informational PurposesAn informational icon, calling your attention
    Note
    If damaged, replace as needed.
  36. Release the tether clips (x6) from the body.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • #2ZPP2 - GearWrench Push Pin Pliers

Install

  1. Attach suction cups to the new fixed roof glass.
  2. With assistance, position the roof glass onto the vehicle for a dry fit.
  3. Make sure the gaps are all within acceptable limits.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the glass is too high, it may be necessary to trim or remove the net pads.
  4. With assistance, remove the roof glass and set it upside-down onto a stand.
  5. Remove the protective tape from the vehicle body.
  6. Clean the glass mating surfaces with isopropyl alcohol, and wait for 1 minute to let the surfaces dry.
  7. Apply primer to the body on the urethane path and any areas that were damaged during removal.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the 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.
  8. Inspect the replacement roof glass for a thick extruded urethane bead.
    • Older roof glass with a thick extruded urethane bead, remove the thick extruded urethane bead before proceeding.
    • Newer roof glass without a thick extruded urethane bead, continue to the next step.
  9. Prepare urethane and a caulking gun with nozzle of 8mm wide and 14mm deep.
  10. Apply urethane to the body.
    • If the vehicle is equipped with roof rack anchors, the urethane should go around the inside of the roof rack anchor.
    • If the vehicle is not equipped with roof rack anchors, the urethane should go on the outside of the anchor mounting holes.
  11. With assistance, place the fixed roof glass onto the vehicle but do not set it yet.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the datums on the LH side of the vehicle at the front and rear corners of glass to the body.
  12. Position the new seal at the front of the glass beneath the windshield seal.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a trim tool to properly seat the roof glass seal under the windshield seal if necessary.
  13. Press the glass onto the body once in position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use sandbags for the front if needed.
  14. Check that the gap and flushness at the liftgate glass, windshield and body sides are within CVIS specification and adjust as necessary.
  15. Remove the suction cups from the fixed roof glass.
  16. Remove the protective tape from the headliner.
  17. Secure the tether clips to the headliner.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that there is an audible click when each clip is seated properly.
  18. Fasten the clips (x18) and hooks (x2) that attach the headliner to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push the coat hook upward and outward to secure hooks to the body flange at the top of the coat hook assembly
  19. Install the bolts (x2) that attach the rear of the headliner to the body.
    3 Nm (2.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are located on the LH and RH sides of the headliner.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  20. Position the RH upper C-pillar trim onto the C-pillar, and then fasten the clips (x7) that attach the trim to the vehicle. Repeat this step for the LH side of the upper C-pillar trim.
    Informational PurposesAn informational icon, calling your attention
    Note
    Replace any damaged clips.
  21. Install the rear trunk parcel shelf. See Parcel Shelf - Rear Trunk (Remove and Replace).
  22. Close the liftgate.
  23. Install the screw that attaches the RH rear coat hook to the headliner.
    2.5 Nm (1.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx T25 socket
  24. Install the RH rear coat hook screw cover.
  25. Push to close the RH rear coat hook.
  26. Repeat step 23 through step 25 for the LH side of the vehicle.
  27. Install the RH and LH upper B-pillar trims. See Trim - B-Pillar - Upper - LH (Remove and Replace).
  28. Fold the LH 2nd row seat to the up position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the seat cushion protection if present.
  29. Install the upper quad camera cover. See Upper Cover - Rear View Mirror (Remove and Replace).
  30. Install the rear view mirror. See Mirror - Rear View (Remove and Replace).
  31. Install the front passenger visor. See Sun Visor - LH (Remove and Replace).
  32. Install the RH upper A-pillar trim. See Trim - A-Pillar - Upper - LH (Remove and Replace).
  33. Install the RH IP end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  34. Install the RH mid A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  35. Repeat step 31 through step 34 for the LH side of the vehicle.
  36. Install the lower quad camera cover. See Camera Cover - Lower (Remove and Replace).