2026-05-21

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. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

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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.

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 the LH front door.
  3. Lower both LH side windows.
  4. Move the LH front seat forward.
  5. Open the LH falcon wing door.
  6. Remove the LH falcon door lower garnish. See Garnish - Lower - Door Trim - Rear - LH (Remove and Replace).
  7. Remove the LH upper falcon door trim. See Panel - Door Trim - Rear - Upper - LH (Remove & Replace).
  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 the LH falcon door.
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to assist the door to close.
  13. Remove the LH falcon door upper glass. See Door Glass Assembly - Rear - Upper - LH (Remove and Replace).
  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. Disconnect the LV battery power. See LV Power (Disconnect and Connect).
  20. Release clips securing harness connectors to closeout panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  21. Disconnect connectors for upper harness
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, 1x connector
  22. Remove bolt securing ground to LH lower falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  23. Remove clips securing harness to LH lower falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips
  24. Mark the position of the lower falcon door to the upper falcon door assembly
  25. 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.
  26. Disconnect both front and rear falcon door strut connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    4x connectors
  27. 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
  28. Remove the front primary strut from upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x C-clip, 1x harness clip
  29. Remove the rear primary strut from upper falcon door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x C-clip, 1x harness clip
  30. 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.
  31. 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
  32. 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
  33. 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
  34. 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
  35. Remove front secondary hinge assembly with clamp bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, E18, 32 Nm, Recommend assistance
  36. Remove rear secondary hinge assembly with clamp bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, E18, 32 Nm, Recommend assistance
  37. 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
  38. 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

Install

Warning IconA warning icon, calling your attention to a possibly risky situation
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 the LV battery power. See LV Power (Disconnect and Connect).
  21. Remove door support stand
  22. 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.
  23. Check the gap and flush of LH falcon door according to specification
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust as needed
  24. 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
  25. Install the LH falcon door upper glass. See Door Glass Assembly - Rear - Upper - LH (Remove and Replace).
  26. Open the LH falcon wing door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust position as required
  27. 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
  28. Install bolts securing LH rear door panel to door
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 10mm, 6 Nm
  29. 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
  30. Install LH upper gap hider trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  31. 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
  32. 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
  33. 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
  34. Install the LH upper falcon door trim. See Panel - Door Trim - Rear - Upper - LH (Remove & Replace).
  35. Install the LH falcon door lower garnish. See Garnish - Lower - Door Trim - Rear - LH (Remove and Replace).
  36. Move the LH front seat to original position.
  37. Raise both LH side windows.
  38. Close the LH front door.