30/05/2024 07:50:00

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.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

  1. Measure the gap and flush of LH falcon door according to specification
    Informational PurposesAn informational icon, calling your attention
    Note
    Record that data and use it as a base line when installing the new door
  2. Open LH front door
  3. Lower both LH side windows
  4. Move LH front seat forward
  5. Open LH falcon wing door
  6. Remove LH falcon door lower garnish
    Informational PurposesAn informational icon, calling your attention
    Note
    9x V-clips, Replace any damaged or missing clips, Take care not to damage door trim panel during removal
  7. Remove LH upper falcon door trim
    Informational PurposesAn informational icon, calling your attention
    Note
    17x clips, 1x connector may be present on early production vehicles
  8. Remove LH falcon rear upper bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
  9. Remove LH falcon front upper bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip
  10. Remove LH upper outer falcon door middle trim
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, T25, 3.0 Nm, 4.0 Nm, Fastener count may vary
  11. Remove LH upper gap hider trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  12. Lower LH falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to assist the door to close
  13. Remove LH falcon door upper glass
    Informational PurposesAn informational icon, calling your attention
    Note
    10x nuts, 10mm, 6 Nm, Recommend assistance
  14. Remove LH rear decor trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips, 2x connectors
  15. Remove bolts securing LH rear door panel to door
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 10mm, 6 Nm
  16. Remove LH rear door trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    13x clips, 2x connectors
  17. Open LH falcon wing door
  18. Support the rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    May need assist to open
  19. Open hood
    Informational PurposesAn informational icon, calling your attention
    Note
    Via center display > Controls > Frunk Open
  20. Remove rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x datums
  21. Power off vehicle via center display
    Informational PurposesAn informational icon, calling your attention
    Note
    Controls > Safety & Security > Power Off
  22. Disconnect LV battery connector and First Responder Loop
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL
  23. Release clips securing harness connectors to closeout panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  24. Disconnect connectors for upper harness
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, 1x connector
  25. Remove bolt securing ground to LH lower falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  26. Remove clips securing harness to LH lower falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips
  27. Mark the position of the lower falcon door to the upper falcon door assembly
  28. Remove the lower falcon door from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 24 Nm, Recommend assistant to hold the lower falcon door.
  29. Disconnect both front and rear falcon door strut connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    4x connectors
  30. Remove the upper falcon door harness clips and route the harness to back of the falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips,Protect the spine applique
  31. Remove the front primary strut from upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x C-clip, 1x harness clip
  32. Remove the rear primary strut from upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x C-clip, 1x harness clip
  33. Pull the upper falcon door lower to mark the hinges
    Informational PurposesAn informational icon, calling your attention
    Note
    The 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.
  34. Remove the LH upper falcon door from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x 13mm bolts, 24Nm, Loosen bolts in closed position, Remove bolts in open position, Recommend assistance if necessary
  35. Lay LH rear door upper harness on top of vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Use fender cover to protect spine and roof glass
  36. Remove front secondary strut with bracket from upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x C-clips, 2x harness clips, 3x bolts, 10mm, 12 Nm
  37. Remove rear secondary strut with bracket from upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x C-clips, 2x harness clips, 3x bolts, 10mm, 12 Nm
  38. Remove front secondary hinge assembly with clamp bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, E18, 32 Nm, Recommend assistance
  39. Remove rear secondary hinge assembly with clamp bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, E18, 32 Nm, Recommend assistance
  40. Remove LH front upper falcon door bump stop assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 8 Nm, 1x screw, T30, 5 Nm
  41. Remove LH rear upper falcon door bump stop assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 8Nm, 1x screw, T30, 5 Nm

Remove

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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.
  1. Use IPA clean NVH seal area of the new upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute drying time
  2. Apply adhesive promoter to NVH seal area of the new upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute drying time
  3. Install new upper falcon door NVH seal to new upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    Use roller to press the seal in place
  4. Install LH front upper falcon door bump stop assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 8Nm, 1x screw, T30, 5 Nm
  5. Install LH rear upper falcon door bump stop assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 8 Nm, 1x screw, T30, 5 Nm
  6. Install the rear secondary hinge assembly with bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, E18, 32 Nm
  7. Install the front secondary hinge assembly with bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, E18, 32 Nm
  8. Install rear secondary strut with bracket from upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x C-clips,2x harness clips, 3x bolts, 10mm, 12 Nm
  9. Install front secondary strut with bracket from upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x C-clips,2x harness clips, 2x bolts, 10mm, 12 Nm
  10. Install the LH upper falcon door and hand tighten bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 24 Nm, Recommend assistance if necessary
  11. Pull the upper falcon door lower and make sure the upper falcon door is aligned and centered before tightening
    Informational PurposesAn informational icon, calling your attention
    Note
    4x 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
  12. Install the rear primary strut to upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x C-clip, 1x harness clip, Door may need to be lifted to align strut, Recommend assistance
  13. Install the front primary strut to upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x C-clip, 1x harness clip, Door may need to be lifted to align strut, Recommend assistance
  14. Install the upper falcon door harness
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips, Replace any broken clips
  15. Connect both front and rear falcon door strut connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    4x connectors
  16. Install the lower falcon door to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x 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
  17. Install clips securing harness to falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  18. Install bolt securing ground to LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  19. Connect three connectors for upper harness
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, 1x connector
  20. Connect First Responder Loop and LV battery connector
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage upper locking tab when fully seated
  21. Install rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x datums
  22. Close hood
  23. Remove door support stand
  24. Calibrate the rear doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.
  25. Check the gap and flush of LH falcon door according to specification
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust as needed
  26. Adjust door as close to specification as possible if necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust 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
  27. Install LH falcon door upper glass
    Informational PurposesAn informational icon, calling your attention
    Note
    10x nuts, 10mm, 6 Nm, Recommend assistance
  28. Open LH falcon wing door
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust position as required
  29. Install LH rear door trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, 13x clips, Install door trim starting from top and make sure the door trim tab is fitted correctly on the inner belt seal
  30. Install bolts securing LH rear door panel to door
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 10mm, 6 Nm
  31. Install LH rear door decor trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips, 2x connectors, Take care not to damage door trim panel
  32. Install LH upper gap hider trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  33. Install LH upper outer falcon door middle trim
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, T25, 3.0 Nm, 4.0 Nm, Fastener count may vary
  34. Install LH falcon front upper bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
  35. Install LH falcon rear upper bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
  36. Install LH upper falcon door trim
    Informational PurposesAn informational icon, calling your attention
    Note
    17x clips, Align strut cover first, 1x connector may be present on early production vehicles
  37. Install LH falcon door lower garnish
    Informational PurposesAn informational icon, calling your attention
    Note
    9x V-clips, 1x guide tab
  38. Move LH front seat to original position
  39. Raise both LH side windows
  40. Close LH front door