Door Assembly - Rear Upper - LH (Remove and Replace)
Correction code 10106702 2.52 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.
Remove
-
Measure the gap and flush of LH falcon
door according to specification
NoteRecord that data and use it as a base line when installing the new door
-
Open LH front door
-
Lower both LH side windows
-
Move LH front seat forward
-
Open LH falcon wing door
-
Remove LH falcon door lower
garnish
Note9x V-clips, Replace any damaged or missing clips, Take care not to damage door trim panel during removal
-
Remove LH upper falcon door trim
Note17x clips, 1x connector may be present on early production vehicles
-
Remove LH falcon rear upper
bracket
Note5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
-
Remove LH falcon front upper
bracket
Note5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip
-
Remove LH upper outer falcon door
middle trim
Note7x bolts, T25, 3.0 Nm, 4.0 Nm, Fastener count may vary
-
Remove LH upper gap hider trim
Note4x clips
-
Lower LH falcon door
NoteMay need to assist the door to close
-
Remove LH falcon door upper glass
Note10x nuts, 10mm, 6 Nm, Recommend assistance
-
Remove LH rear decor trim panel
Note7x clips, 2x connectors
-
Remove bolts securing LH rear door
panel to door
Note8x bolts, 10mm, 6 Nm
-
Remove LH rear door trim panel
Note13x clips, 2x connectors
-
Open LH falcon wing door
-
Support the rear door
NoteMay need assist to open
-
Open hood
NoteVia center display > Controls > Frunk Open
-
Remove rear underhood apron
Note11x clips, 2x datums
-
Power off vehicle via center
display
NoteControls > Safety & Security > Power Off
-
Disconnect LV battery connector and
First Responder Loop
Note2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL
-
Release clips securing harness
connectors to closeout panel
Note3x clips
-
Disconnect connectors for upper
harness
Note2x locking connectors, 1x connector
-
Remove bolt securing ground to LH
lower falcon door
Note1x bolt, 10mm, 10 Nm
-
Remove clips securing harness to LH
lower falcon door
Note5x clips
-
Mark the position of the lower falcon
door to the upper falcon door assembly
-
Remove the lower falcon door from
vehicle
Note4x bolts, 13mm, 24 Nm, Recommend assistant to hold the lower falcon door.
-
Disconnect both front and rear falcon
door strut connectors
Note4x connectors
-
Remove the upper falcon door harness
clips and route the harness to back of the falcon door
Note7x clips,Protect the spine applique
-
Remove the front primary strut from
upper falcon door
Note1x C-clip, 1x harness clip
-
Remove the rear primary strut from
upper falcon door
Note1x C-clip, 1x harness clip
-
Pull the upper falcon door lower to
mark the hinges
NoteThe upper door is still spring loaded, Recommend assistance if necessary, Caution: the upper falcon door hinges are spring loaded and will retract to the open position.
-
Remove the LH upper falcon door from
vehicle
Note4x 13mm bolts, 24Nm, Loosen bolts in closed position, Remove bolts in open position, Recommend assistance if necessary
-
Lay LH rear door upper harness on top
of vehicle
NoteUse fender cover to protect spine and roof glass
-
Remove front secondary strut with
bracket from upper falcon door
Note1x C-clips, 2x harness clips, 3x bolts, 10mm, 12 Nm
-
Remove rear secondary strut with
bracket from upper falcon door
Note1x C-clips, 2x harness clips, 3x bolts, 10mm, 12 Nm
-
Remove front secondary hinge assembly
with clamp bracket
Note3x bolts, E18, 32 Nm, Recommend assistance
-
Remove rear secondary hinge assembly
with clamp bracket
Note3x bolts, E18, 32 Nm, Recommend assistance
-
Remove LH front upper falcon door bump
stop assembly
Note2x bolts, 10mm, 8 Nm, 1x screw, T30, 5 Nm
-
Remove LH rear upper falcon door bump
stop assembly
Note2x bolts, 10mm, 8Nm, 1x screw, T30, 5 Nm
Remove
-
Use IPA clean NVH seal area of the new
upper falcon door
NoteAllow 1 minute drying time
-
Apply adhesive promoter to NVH seal
area of the new upper falcon door
NoteAllow 1 minute drying time
-
Install new upper falcon door NVH seal
to new upper falcon door
NoteUse roller to press the seal in place
-
Install LH front upper falcon door
bump stop assembly
Note2x bolts, 10mm, 8Nm, 1x screw, T30, 5 Nm
-
Install LH rear upper falcon door bump
stop assembly
Note2x bolts, 10mm, 8 Nm, 1x screw, T30, 5 Nm
-
Install the rear secondary hinge
assembly with bracket
Note3x bolts, E18, 32 Nm
-
Install the front secondary hinge
assembly with bracket
Note3x bolts, E18, 32 Nm
-
Install rear secondary strut with
bracket from upper falcon door
Note1x C-clips,2x harness clips, 3x bolts, 10mm, 12 Nm
-
Install front secondary strut with
bracket from upper falcon door
Note1x C-clips,2x harness clips, 2x bolts, 10mm, 12 Nm
-
Install the LH upper falcon door and
hand tighten bolts
Note4x bolts, 13mm, 24 Nm, Recommend assistance if necessary
-
Pull the upper falcon door lower and
make sure the upper falcon door is aligned and centered before tightening
Note4x bolts, 13mm, 24 Nm, Use a rubber hammer to position upper falcon door to previous marked location, Use caution as the falcon door hinges are spring loaded and will want to retract to falcon door open position, Recommend assistance
-
Install the rear primary strut to
upper falcon door
Note1x C-clip, 1x harness clip, Door may need to be lifted to align strut, Recommend assistance
-
Install the front primary strut to
upper falcon door
Note1x C-clip, 1x harness clip, Door may need to be lifted to align strut, Recommend assistance
-
Install the upper falcon door harness
Note7x clips, Replace any broken clips
-
Connect both front and rear falcon
door strut connectors
Note4x connectors
-
Install the lower falcon door to
vehicle
Note4x bolts, 13mm, 24 Nm, Recommend assistant to hold the lower falcon door, Ensure the lower falcon door hinges align with marked position before tightening bolts
-
Install clips securing harness to
falcon door
Note4x clips
-
Install bolt securing ground to LH
rear door
Note1x bolt, 10mm, 10 Nm
-
Connect three connectors for upper
harness
Note2x locking connectors, 1x connector
-
Connect First Responder Loop and LV
battery connector
Note2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage upper locking tab when fully seated
-
Install rear underhood apron
Note11x clips, 2x datums
-
Close hood
-
Remove door support stand
-
Calibrate the rear doors.
NoteIf the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.
-
Check the gap and flush of LH falcon
door according to specification
NoteAdjust as needed
-
Adjust door as close to specification
as possible if necessary
NoteAdjust the lower falcon door hinges, the upper corner of the lower falcon door should be adjust a bit under flush at this time, the struts should push it out once installed. Recommend assistance, 6x bolts, E18, 32 Nm, 4x bolts, 13mm, 24 Nm
-
Install LH falcon door upper
glass
Note10x nuts, 10mm, 6 Nm, Recommend assistance
-
Open LH falcon wing door
NoteAdjust position as required
-
Install LH rear door trim panel
Note2x connectors, 13x clips, Install door trim starting from top and make sure the door trim tab is fitted correctly on the inner belt seal
-
Install bolts securing LH rear door
panel to door
Note8x bolts, 10mm, 6 Nm
-
Install LH rear door decor trim
panel
Note7x clips, 2x connectors, Take care not to damage door trim panel
-
Install LH upper gap hider trim
Note4x clips
-
Install LH upper outer falcon door
middle trim
Note7x bolts, T25, 3.0 Nm, 4.0 Nm, Fastener count may vary
-
Install LH falcon front upper
bracket
Note5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
-
Install LH falcon rear upper
bracket
Note5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
-
Install LH upper falcon door
trim
Note17x clips, Align strut cover first, 1x connector may be present on early production vehicles
-
Install LH falcon door lower
garnish
Note9x V-clips, 1x guide tab
-
Move LH front seat to original
position
-
Raise both LH side windows
- Close LH front door