30/05/2024 08:25:07
Liftgate Assembly (Remove and Replace)
FRT No: 10107002
- 2023-11-16: Added note to the beginning of this procedure for vehicles with manual liftgates.
- 2023-10-25: All replacement liftgates must be reworked so that they can be installed on classic Model S. This procedure has been updated to include rework instructions.
Note
Vehicles with manual liftgates: procure and install the liftgate pinch sensors
as instructed in this procedure. Tape and secure the pinch sensor harnesses so as to
prevent potential NVH.
Removal
-
Open all four doors
-
Lower all four windows
-
Move LH front seat forward
-
Move RH front seat forward
-
Fold 60 and 40 seat into down
position
-
Remove rear license plate
Note4x screws, phillips head
-
Open liftgate
-
Remove parcel shelf
-
Remove trunk load floor
-
Remove upper liftgate trim
Note4x clips, Replace any damaged clips
-
Remove liftgate LH side trim
panel
Note3x clips, Replace any damaged clips
-
Remove liftgate RH side trim
panel
Note3x clips, Replace any damaged clips
-
Remove pull cups from lower
liftgate trim assembly
Note1x connector, If equipped with power liftgate
-
Remove screws securing lower
liftgate trim to body
Note2x screws, T20, 3 Nm
-
Remove lower liftgate trim
Note10x clips, 4x connectors, Number of connections may vary, Take care not to damage connectors when releasing trim
-
Disconnect CHMSL
Note1x connector
-
Remove LH antenna amplifier
Note1x screw, T25, 1.2 Nm, 3x connectors
-
Remove LH RF filter
Note1x bolt, T30, 2 Nm, 1x connector, Discard after removal
-
Remove RH antenna amplifier
Note1x screw, T25, 1.2 Nm, 2x connector
-
Remove RH RF filter
Note1x bolt, T30, 2 Nm, 2x connector, Discard after removal, Remove component from wiring harness
-
Disconnect RH tail lamp
Note1x connector
-
Disconnect LH tail lamp
Note1x connector
-
Remove bolt securing liftgate
grounding terminals
Note1x bolt, 10mm, 9 Nm, 2x ground terminals
-
Remove clips securing harnesses
to liftgate assembly
Note13x fir tree clips, 1x edge clip
-
Tuck the exposed wire harness
into the rear liftgate
NoteCaution not to damaged harness when closing the liftgate in the next step
-
Close liftgate
-
Remove liftgate applique
Note5x clips Recommend using the badge removal wire to release adhesive on the tail lamps, Note the center of the applique is secured by clips, Take care not to damage applique or body
-
Open liftgate
-
Remove LH reverse tail lamp from
liftgate
Note4x nuts, 8mm, 4 Nm, 2x rubber covers, Remove rubber covers
-
Remove RH reverse tail lamp from
liftgate
Note4x nuts, 8mm, 4 Nm, 2x rubber covers, Remove rubber covers
-
Disconnect LH liftgate pinch
strip sensor
Note1x connector
-
Remove LH rear liftgate pinch
strip assembly from the liftgate
Note6x push clip
-
Remove LH pinch strip grommet and
remove the pinch strip from the liftgate
Note1x grommet
-
Disconnect RH liftgate pinch
strip sensor
Note1x connector
-
Remove RH rear liftgate pinch
strip assembly from the liftgate
Note6x push clip
-
Remove RH pinch strip grommet and
remove the pinch strip from the liftgate
Note1x grommet
-
Remove bolts and screws securing
rear view camera to bracket and bracket to liftgate
Note3x screws, T20, 2.4 Nm, 2x bolt, T25, 2.4 Nm, Discard rear view camera bolts after removal
-
Install protective tape on rear
view camera
-
Remove rear view camera from
liftgate
Note1x connector, 1x grommet, Take care not to let the rear view camera drop on the ground when releasing it from the liftgate
-
Remove LH and RH license plate
lamps
Note2x connector, 2x lamps, Depress the locking tab on the license plate lamp to release
-
Close liftgate
-
Clean rear glass and secure
double suction cup handles onto both side of liftgate glass
-
Apply tape to body surrounding
liftgate glass for protection
-
Cut length of square wire to use
with T-handles
NoteMake sure there's adequate wire
-
Attach one side of wire to a
T-handle
-
Secure wire to starter tool and
push tool through urethane at upper left side
NotePush starter wire tool in between liftgate glass and CHMSL
-
Remove wire from starter tool and
secure square wire into one T-handle
-
Remove wire starter tool from
vehicle
-
Cut out and remove rear liftgate
glass
NoteRecommend assistance, if wire is getting caught on center high mounted stop lamp, equalizer can be used to separate CHMSL from liftgate glass
-
Remove protective tape from
body
NoteInspect for any nicks that may need touch up
-
Remove urethane from the liftgate
glass and body
NoteA recommended method for this step is to grip a razor blade with a pair of pliers. Touch the blade to the body and gently push downwards
-
Open liftgate
-
Remove LH and RH liftgate drain
plug
Note2x drain plug
-
Remove bolts securing LH and RH
liftgate wedge bumpers to liftgate
Note2x bolt, T30, 12 Nm, 2x caps
-
Remove LH and RH lower bumps from
liftgate
Note2x bump stop
-
Disconnect liftgate latch
Note1x connector
-
Remove liftgate latch emergency
release cable from rear liftgate
Note1x edge clip
-
Remove emergency liftgate release
cable tether from end of release cable
NotePeel of the butyl and remove cable
-
Remove liftgate latch assembly
from liftgate
Note2x bolts, T30, 10 Nm
-
Remove bolts securing liftgate
release button to liftgate
Note2x bolts, 10mm / T30, 3 Nm
-
Remove liftgate release button
from liftgate
Note1x connector
-
Release RH liftgate harness
grommet from liftgate
Note1x grommet
-
Place a fender cover on vehicle
RH side
-
Pull wire harness through RH top
liftgate grommet hole
-
Release LH liftgate harness
grommet from body
Note1x grommet
-
Place a fender cover on vehicle
LH side
-
Route LH liftgate harness through
grommet hole
-
Disconnect GPS antenna from LH
liftgate harness
NoteRemove tape as needed
-
Remove GPS antenna from
liftgate
-
Support liftgate
NoteNeed assistance
-
Disconnect LH and RH liftgate
struts from liftgate
Note2x strut clip
-
Remove LH liftgate strut ball
stud from liftgate
Note1x patched ball stud, 13mm, 22 Nm, Discard after removal
-
Remove RH liftgate strut ball
stud from liftgate
Note1x patched ball stud, 13mm, 22 Nm, Discard after removal
-
Remove RH rear C-pillar
trim
Note1x screw, T25, 3 Nm, 4x clips
-
Remove RH upper C-pillar
trim
Note4x clips
-
Remove bolt securing headliner
and support strap at RH C-pillar
Note1x bolt, 8mm, 10 Nm
-
Remove LH rear C-pillar
trim
Note1x screw, T25, 3 Nm, 4x clips
-
Remove LH C-pillar upper
trim
Note4x clips
-
Remove bolt securing headliner
and support strap at LH C-pillar
Note1x bolt, 8mm, 10 Nm
-
Release rear of headliner and
lower
Note5x clips, 3x velcro strips
-
Close liftgate
-
Remove nuts securing liftgate
hinge to body
Note4x nuts, 10mm, 16 Nm, Remove from inside of the vehicle, Move butyl patch aside to expose nuts securing liftgate hinge to body
-
Remove liftgate from
vehicle
NoteRecommend assistance
Install
CAUTION
If using this procedure to
install an unpainted part, make sure to apply seam sealer to all seams prior to
installing and painting the part. Refer to the Collision Repair manual for more
information.
-
Prepare liftgate for
installation
-
Install RH liftgate strut ball
stud onto liftgate
Note1x patched ball stud, 13mm, 22 Nm, Install new patched ball stud
-
Install LH liftgate strut ball
stud onto liftgate
Note1x patched ball stud, 13mm, 22 Nm, Install new patched ball stud
-
Install liftgate onto
vehicle
Note4x nuts, 10mm, 16 Nm, Recommend assistance, Do not fully tighten the liftgate in this step
-
Connect RH liftgate strut onto
liftgate
Note1x strut clip
-
Connect LH liftgate strut onto
liftgate
Note1x strut clip
-
Install license plate frame screw
grommets onto liftgate
Note4x screw grommets
-
Install applique bracket screw
grommets onto liftgate
Note3x screw grommets
-
Use tape and wrap up right side
wire harness to protect connectors during installation
-
Use tape and wrap up left side
wire harness to protect connectors during installation
-
Route RH liftgate harness through
grommet hole
NoteUse zip ties and tape as needed
-
Secure RH liftgate harness
grommet onto liftgate
Note1x grommet, Apply P-80 onto grommet for easier fit
-
Route LH liftgate harness through
grommet hole
NoteUse zip ties as needed
-
Route GPS antenna connector
through LH top liftgate grommet hole
NoteRoute GPS antenna from outside, Remove red double sided tape cover and attach GPS antenna onto liftgate
-
Connect GPS antenna onto LH
liftgate harness
Note1x connector, apply tape as needed
-
Secure LH liftgate harness
grommet onto body
Note1x grommet, Apply P-80 onto grommet for easier fit, Make sure its fully installed
-
Connect RH liftgate pinch strip
sensor
Note1x connector, Route harness trough RH liftgate grommet opening
-
Install RH pinch strip grommet
onto liftgate
Note1x grommet, Apply P-80 onto grommet for easier fit
-
Install RH rear liftgate pinch
strip assembly onto liftgate
Note6x push clip
-
Connect LH liftgate pinch strip
sensor
Note1x connector, Route harness trough LH liftgate grommet opening
-
Install LH pinch strip grommet
onto liftgate
Note1x grommet, Apply P-80 onto grommet for easier fit
-
Install LH rear liftgate pinch
strip assembly onto liftgate
Note6x push clip
-
Remove protective tape from RH
side liftgate wire harness
-
Remove protective tape from LH
side liftgate wire harness
-
Install clips securing harnesses
to liftgate assembly
Note13x fir tree clips, 1x edge clip
-
Remove painted ground bolts from
liftgate
Note7x bolts, 10mm, 9 Nm, Preparing for later mounting
-
Install RH reverse tail lamp onto
liftgate
Note4x nuts, 8mm, 4 Nm, 2x rubber covers
-
Install LH reverse tail lamp onto
liftgate
Note4x nuts, 8mm, 4 Nm, 2x rubber covers
-
Connect RH tail lamp
Note1x connector
-
Connect LH tail lamp
Note1x connector
-
Install RH lower bump onto
liftgate
Note1x bump stop
-
Install LH lower bump onto
liftgate
Note1x bump stop
-
Install liftgate grounding
terminals
Note2x bolt, 10mm, 9 Nm, 2x ground terminals
-
Install liftgate latch assembly
onto liftgate
Note2x bolts, T30, 10 Nm
-
Connect liftgate latch
Note1x connector
-
Install liftgate latch emergency
release cable onto rear liftgate
Note1x edge clip
-
Install emergency liftgate
release cable tether onto end of release cable
NoteUse new piece of butyl tape if old doesn't hold
-
Install rear liftgate emergency
cable into place
Note1x edge clip, To avoid NVH issues make sure the cable is firmly secured
-
Install piece of dual lock onto
rear liftgate
NoteInstall in area near emergency release cable, Used as an anchor for the emergency release cable
-
Install liftgate release button
onto liftgate
Note1x connector
-
Install bolts securing liftgate
release button to liftgate
Note2x bolts, 10mm, 3 Nm
-
Install RH license plate lamp
onto liftgate
NoteMake sure you hear the locking tab snap into place holding the plate light in place
-
Connect RH license plate
lamp
Note1x connector
-
Install LH license plate lamp
onto liftgate
NoteMake sure you hear the locking tab snap into place holding the plate light in place
-
Connect LH license plate
lamp
Note1x connector
-
Install LH and RH liftgate drain
plug
Note2x drain plug
-
Install rear view camera harness
onto liftgate
Note1x edge clip
-
Install rear view camera into
liftgate
Note1x grommet, Apply P-80 onto grommet for easier fit
-
Connect rear view camera
Note1x connector 1x clip
-
Remove protective tape from rear
view camera
-
Install bolts securing rear view
camera onto bracket
Note2x bolt, T25, 2.4 Nm, Install new patched bolts, Thread the rear facing camera into the rear liftgate applique bracket
-
Install screws securing bracket
onto liftgate
Note3x screws, T20, 2.4 Nm
-
Install RH liftgate wedge bumper
onto liftgate
Note1x bolt, T30, 12 Nm, 1x cap
-
Install LH liftgate wedge bumper
onto liftgate
Note1x bolt, T30, 12 Nm, 1x cap
-
Inspect that all harness clips
are in place
NoteMake sure that harness will not get damaged if the rear liftgate is closed
-
Close liftgate
-
Check gap and flush from liftgate
to body
NoteReference gap and flush specification guide on service manual, Adjust if needed, https://service.teslamotors.com/protected-doc/ModelS/TheoryOp/InspectionStandards/index_frames.html
-
Torque nuts securing liftgate
hinge to body
Note4x nuts, 10mm, 16 Nm, Torque from inside of the vehicle
-
Use an IPA wipe to clean CHMSL
mounting location
NoteAllow IPA to dry for at least one minute
-
Use an IPA wipe to clean urethane
path on liftgate glass
NoteAllow IPA to dry for at least one minute
-
Use an IPA wipe to clean urethane
path on body
NoteAllow IPA to dry for at least one minute
-
Print out CHMSL template and cut
it out
Notehttp://toolbox.teslamotors.com/media/attachments/shared/7741afaa-ded3-4e7b-b003-209c5678960a.pdf
-
Place CHMSL templates on liftgate
glass in upper corner of glass and secure template with tape
-
Reconnect the CHMSL to the
harness in the center of the liftgate
Note1x connector
-
Test if CHMSL is working
correctly
NoteHave an assistant depress the brake pedal, Ensure that the CHMSL lights up properly, If any of the LEDs have been damaged, Replace the CHMSL, If wire has been damaged repair wire following bulletin, https://service.teslamotors.com/protected-doc/ServiceBulletins/Internal/SI/SI-17-17-002_Electrical_Harness_Repair_R6.pdf
-
Disconnect CHMSL assembly
Note1x connector
-
Remove old double sided tape from
CHMSL
NoteUse glue remover
-
Use an IPA wipe to clean double
sided tape path on CHMSL assembly
NoteAllow IPA to dry for at least one minute
-
Apply new double sided tape to
CHMSL
-
Remove red tape covers from
CHMSL
-
Secure CHMSL to liftgate
glass
NotePlace in upper corners of template, Apply pressure to adhere 3M tape to liftgate glass
-
Remove CHMSL templates from
liftgate glass
-
Secure CHMSL harness to liftgate
glass
-
Secure double suction cup to
outside of new rear liftgate glass
Note2x double suction cup handles, 1 on each side of glass
-
Flip over rear liftgate glass and
install it onto vehicle
Note2x double suction cup handles, 1 on each side of glass, Recommend assistance
-
Check gap and flush of liftgate
glass
NoteMake notes of any needed adjustments
-
Remove rear liftgate glass
Note2x double suction cup handles, 1 on each side of glass
-
Apply urethane primer to liftgate
glass along urethane path
NoteAllow primer to dry for 2 minutes before applying urethane
-
Apply urethane primer to liftgate
body along urethane path
NoteAllow primer to dry for 2 minutes before applying urethane
-
Prepare caulking gun and
urethane
NoteOpening must be 8mm wide and 14mm tall
-
Apply urethane to liftgate body
following primer patch
NoteFill any gaps in urethane to ensure consistent bead
-
Flip over rear liftgate glass and
install it onto vehicle
Note2x double suction cup handles, 1 on each side of glass, Recommend assistance
-
Check gap and flush of liftgate
glass
NoteUse tape to hold glass in place, allow glass 10 minutes of dry time before opening liftgate
-
Remove suction cups from liftgate
glass
Note2x double suction cup handles
-
Clean adhesive from applique
bracket and liftgate tail lamp assembly
NoteClean off residue, Recommend using your thumb to help roll off the adhesive, Allow 1 minute for IPA to dry
-
Install applique tape onto
applique bracket and applique
NoteBe careful not to cover the rear view camera
-
Remove adhesive backing from
applique bracket and liftgate applique
-
Install the liftgate
applique
Note5x clips, Align applique using pin, Start by securing center clips and work your way out towards the tail lamps, Do not allow the ends to adhere before securing the center
-
Install "Model S" badge onto
liftgate
NoteUse an IPA wipe to clean area, Allow IPA to dry for at least one minute
-
Install Tesla "T" badge onto
liftgate
NoteUse an IPA wipe to clean area, Allow IPA to dry for at least one minute
-
Install "Battery Size" badge onto
liftgate
NoteUse an IPA wipe to clean area, Allow IPA to dry for at least one minute
-
Open liftgate
NoteAllow for dry time
-
Untuck the protected rear
liftgate wire harness
-
Install LH and RH lower liftgate
trim screw grommets
Note2x screw grommet
-
Install RH RF filter
Note1x bolt, T30, 2 Nm, 2x connectors, Install new patch bolt
-
Rework LH and RH antenna
amplifiers
Note2x clips, 2x tabs, Remove clip from tab then using side cutter pliers cut off tab, File off excess material to create flush surface, Apply double sided tape onto antenna amplifiers, Careful damage antenna amplifiers when reworking
-
Install RH antenna
amplifier
Note1x screw, T25 / 10mm, 1.2 Nm, 2x connector
-
Connect CHMSL
Note1x connector
-
Install LH RF filter
Note1x bolt, T30, 2 Nm, 1x connector, Install new patched bolt
-
Install LH antenna
amplifier
Note1x screw, T25 / 10mm, 1.2 Nm, 2x connectors
-
Install lower liftgate trim
Note10x clips, 4x connectors, Number of connections may vary, Replace any damaged clips
-
Install RH side liftgate
trim
Note3x clips, Replace any damaged clips
-
Install LH side liftgate
trim
Note3x clips, Replace any damaged clips
-
Install upper liftgate trim
Note4x clips, Replace any damaged clips
-
Install parcel shelf
-
Install trunk load floor
-
Install rear portion of headliner
into position and clip into place
Note5x clips, 3x velcro strips, Replace any damaged or missing clips
-
Install bolt securing headliner
and support strap at LH C-pillar
Note1x bolt, 8mm, 10 Nm
-
Install LH C-pillar upper
trim
Note4x clips
-
Install LH rear C-pillar
trim
Note1x screw, T25, 3 Nm, 4x clips
-
Install bolt securing headliner
and support strap at RH C-pillar
Note1x bolt, 8mm, 10 Nm
-
Install RH upper C-pillar
trim
Note4x clips
-
Install RH rear C-pillar
trim
Note1x screw, T25, 3 Nm, 4x clips
-
Install liftgate pull cups into
rear liftgate
Note1x connector, If equipped with power liftgate
-
Close liftgate
-
Fold 60 and 40 seat into vertical
position
-
Close all doors
-
Return RH front seat to original
position
-
Return LH front seat to original
position
NoteUtilize driver profile settings to return customer seat settings if saved
-
Raise all four windows
-
Close both front doors