07/03/2024 06:26:15

Handle - Exterior Release - Door - Rear - LH - Generation 3.0 (Retrofit)

Correction Code 11452006

  • 2024-03-07: Updated topic to latest procedure validation.
  • 2023-10-25: Rearranged installation steps and added extra note.
  • 2023-08-30: Revised title for the hyperlink for the recalibration procedure.
Special tools required for this procedure:
Part Number Description
1454796-00-A Window switch tool (rear)
1080985-10-A Door handle alignment kit

Generation 2.5 Handle Assembly Removal

  1. Open the LH rear door and lower the window.
  2. Remove the LH rear door trim panel. See Panel - Door Trim - Rear - LH (Remove and Install).
  3. Apply masking tapes on the outside of the vehicle to mark the position of the window glass relative to the outer belt.
  4. Apply masking tape to cover the outside of the LH rear door handle grip.
  5. Latch the LH rear door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Latching the door makes the door glass move into the fully closed position (all the way up). Do not close door with the window in the fully closed position due to the risk of breaking the glass.
  6. Connect the window switch tool to the door wiring harness.
  7. Remove and discard the LH rear door closeout panel.
  8. Remove the door glass Door Glass - LH - Rear (Remove and Replace) and put the glass in a safe location during the remainder of the procedure.
  9. Remove the upper rear nut that attaches the rear window regulator assembly to the door.
  10. Use the window switch tool to move the window regulator to the lowest position.
  11. Mark the lower position of the regulator on the inner door.
  12. Remove the rear lower access cover for the LH rear lower window regulator nu. and then remove the lower rear nut that attaches the LH rear regulator assembly (torque 7.5 Nm).
  13. Move the rear portion of the window regulator track towards front of door cavity.
  14. Using a pry tool, remove the fir tree clip that attaches the door handle harness inside the door cavity, and then disconnect the LH rear door handle connector.
  15. Release the door handle harness edge clips (x2) from the inner door cavity.
  16. Remove the nuts (x4) that attach the LH rear door handle to the door.
  17. Remove the door handle assembly from the vehicle.
  18. Remove the rear door handle back plate from the LH rear grip.
  19. Remove the LH rear door handle grip from the door handle assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    The door handle of the factory installed Model S door handle assembly is made from metal. Replacement door handles are plastic and slightly smaller than the factory-installed original handle. The door handle must be transferred from the original door handle assembly to the replacement assembly to maintain consistency with the rest of the door handles installed on the vehicle if equipped with factory installed door handles.

Generation 3.0 Handle Assembly Installation

  1. Remove the screws (x5) that attach the new door handle assembly rear cover.
  2. Remove the screws (x4) that attach the back plate to the handle grip, and then remove the back plate from the assembly.
  3. Remove the plastic door grip from the door handle assembly.
  4. Install spacers on the handle fork.
    Informational PurposesAn informational icon, calling your attention
    Note
    When transferring a factory-installed door handle to the replacement door handle assembly, spacers are required to maintain a good fit of the metal door handle to the slightly smaller grip cartridge of the replacement door handle assembly.
    1. Remove the tape covering the adhesive on the spacer for the front-most fork arm.
    2. Place the spacer, with the adhesive side down, on the front-most fork arm so that the angled edge is oriented correctly to the fork arm, and the hole in the center of the spacer aligns with the hole on the grip-side of the fork handle.
    3. Remove the tape covering the adhesive on the spacer for the rear-most fork arm.
    4. Place the spacer, with the adhesive side down, on the rear-most fork arm so that the angled edge is oriented correctly to the fork arm, and the hole in the center of the spacer aligns with the hole on the grip-side of the fork handle.
    5. Remove the tape covering the adhesive on the second spacer for the rear-most fork arm.
    6. Place the spacer, with the adhesive side down, in the center of the small flat area above the hole on the rearmost fork arm.
  5. Install the metal door grip from the original door handle assembly in the replacement door handle assembly.
  6. Install the painted back plate from the old door handle assembly, and then tighten the bolts (x4) that attach the back plate to the handle grip (torque 2 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the handle was not equipped with an LED because it was a base version, install a dummy plug (1118491-00-A) in the empty cavity to prevent water ingress. If a dummy plug is not available, tape can be used to seal the connector cavity instead.
  7. Install the door handle assembly rear cover, and then tighten the screws (x5) that attach the cover to the assembly (torque 2 Nm).
  8. Connect the door handle harness to the door handle assembly.
  9. Apply LOCTITE 222 Threadlocking Adhesive onto the nuts that attach the door handle assembly to the front door assembly.
  10. Install the door handle assembly in the door body, and hand tighten the nuts (x4).
  11. Remove the masking tape from the outside of the LH front door handle grip.
  12. Use the door handle alignment tool, part number 1080985-00-A (LH alignment tool) or 1080985-01-A (RH alignment tool) to align the door handle.
  13. Tighten the nuts (x4) that attach the door handle assembly to the door outer panel (torque 9 Nm).
  14. Adjust the exterior edge of the door handle grip to be flush with the outside of the door panel. Tighten or loosen the T40 screw on the rear of the door handle assembly to move the door handle in or out.
  15. Make sure the front and rear of the door handle are flush with the outside of the door panel and the handle fit is consistent with the other door handles on the vehicle.
    1. If the door handle alignment is correct, go to step 16.
    2. If the door handle appearance is not consistent with the other handles installed on the vehicle, remove the nuts installed in step 13.
    3. To achieve a fit consistent with the other door handles on the vehicle, install or remove shims around the door handle mounting studs on the inboard side of the door panel.
      Informational PurposesAn informational icon, calling your attention
      Note
      To achieve the correct fit, 1 shim (1.5mm thick) on each door handle mounting stud is nominal. If necessary to achieve the correct fit, try combinations of 1 or 2 shims, up to a total of 3.0 mm total thickness for all shims on any of the 4 door handle mounting studs.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Failure to properly align the door handle with the outside of the door panel can result in improper fitment, and therefore repeat repair of the door handle.
    4. Repeat step 12 through step15 as necessary to achieve the correct fit.
  16. Install the door handle harness clip to the inner door.
  17. Return the rear portion of the window regulator to the marked position.
  18. Hand tighten the nuts (x2) that attach the LH rear window regulator track.
  19. Install the door glass Door Glass - LH - Rear (Remove and Replace) and raise the window.
  20. Adjust the door glass to the previously marked position on the outer belt seal.
  21. Remove the tape from the window glass.
  22. Tighten the nuts (x2) that attach the top part of the regulator to the door (torque 7.5 Nm).
  23. Tighten the nut (x1) that attaches the lower part of the regulator to the door (torque 7.5 Nm).
  24. Reinstall the plug covering the nut that attaches the regulator to the bottom rear part of the door.
  25. Carefully reinstall the door glass seal, starting from the rear part of the door, and moving towards the front.
  26. Install butyl patches covering the LH rear door access holes for the window regulator and handle hardware.
  27. Align the new closeout panel with the regulator access opening inside the door frame and use masking tape to temporarily attach the panel in place.
    Tip: Make sure the new closeout panel is evenly aligned around the regulator access opening.
  28. Use a paint pen to mark the locations (x5) for the mounting holes.
    Tip: Do not to move the closeout panel when applying marks for mounting points.
  29. Drill a 3.5 mm hole at each of the marked locations (x5).
    Tip: For best results, and to catch some of the metal shavings, apply a coating of white lithium grease to the drill bit and drill at low speed.
  30. Wipe off the freshly drilled surfaces (inside and outside the door frame) and clean metal shavings from inside the door cavity.
  31. Drill a 25 mm hole in the closeout panel where indicated on the inboard side of the closeout panel.
  32. Connect the door handle wiring harness connector to the door harness.
  33. Attach the door handle wiring harness to the inner door frame with a push clip and attach the door handle wiring harness clip to the door.
  34. Route the door handle harness through the hole in the closeout panel and seat the sealing grommet.
  35. Install the updated closeout panel and make sure the manual door handle release cable is routed properly.
  36. Install the screws (x5) that attach the closeout panel to the door frame (torque 4 Nm).
  37. Insert the tabs on the bottom of the door handle module into the retainers on the closeout panel.
  38. Install and tighten the screw (x1) to hold the top of the door handle module to the closeout panel (torque 2 Nm).
  39. Connect the door handle wiring harness to the door handle module mounted on the closeout panel.
  40. Connect the window switch tool to the door harness connector.
  41. Raise and lower the window several times and make sure the door handle wiring harness and connectors are not in the path of the window glass as it moves up and down.
  42. Disconnect the window switch tool from the door harness connector.
  43. Connect the door handle wiring harness to the door handle module mounted on the closeout panel.
  44. Install the LH rear door trim panel. See Panel - Door Trim - Rear - LH (Remove and Install).
  45. Release LH rear door latch.
  46. Use the touchscreen to perform the door exterior release handle recalibration procedure. See Handle - Exterior Release - Door (Recalibrate).
  47. Perform a firmware reinstall. See Firmware Reinstall - Touchscreen.
  48. Verify the operation of all door handles.