10/12/2024 13:17:33

Backlight Glass (Remove and Replace)

Correction code 10204002 1.56 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.

  • 2024-12-10: Added new caution about Pre-Installation Glass Inspection service requirements.
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CAUTION
For Europe only: Only technicians who have been trained in working with diisocyanates and have completed all required certification courses are permitted to perform procedures using urethane and other products containing diisocyanates. Proper personal protective equipment (PPE) must be worn when working with products containing diisocyanates.
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CAUTION
New glass components (windshield, roof, door, and fixed glass) must be inspected before installation to meet Tesla’s internal standards of quality. Perform the inspection described in Pre-Installation Glass Inspection before beginning this procedure.

Remove

  1. Open the LH front door.
  2. Lower the LH front window.
  3. Open the liftgate.
  4. Remove the lower liftgate trim. See Trim - Liftgate - Lower (Remove and Replace).
  5. Remove the liftgate speaker grille. See Grille - Speaker - Liftgate (Remove and Replace).
  6. Remove the liftgate upper trim. See Trim - Upper - Liftgate (Remove and Replace).
  7. Remove the RH active spoiler catch basin cover. See Cover - Catch Basin - Active Spoiler - LH (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the harness from the catch basin cover.
  8. Release the clip that attaches the CHMSL lamp harness connector to the liftgate, and then disconnect the connector.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Clip pry tool
  9. Remove the LH active spoiler catch basin cover. See Cover - Catch Basin - Active Spoiler - LH (Remove and Replace).
  10. Disconnect the LH and RH defroster grid and antenna connectors (x4).
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Plastic trim tool
  11. Close the liftgate.
  12. Remove the spoiler applique. See Applique - Spoiler (Remove and Install).
  13. Remove the screws (x4) that attach the passive spoiler assembly to the vehicle, and then remove the spoiler from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 6 in extension
    • Flex head ratchet/flex head torque wrench
    • Torx T30 socket
  14. Open the liftgate.
  15. Remove the push clips (x2) that attach the LH upper pinch strip to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Pocket screwdriver
  16. Disconnect the LH upper rear liftgate pinch strip harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the connector out of the way, and then tape the connector to the liftgate.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Masking tape
  17. Remove the upper liftgate glass seal.
  18. Use the equalizer blade to cut the adhesive on the top portion of the backlight glass.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Equalizer blade - 1083427-00-A
    • Safety glasses
  19. Cut an appropriate length of square wire.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Diagonal cutters
    • Safety glasses
    • T-Handles - 1078806-00-A
  20. Insert the wire starter through the adhesive near one of the upper backlight glass corners, pull the wire through, and then remove the wire starter from the backlight glass.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Wire starter - 1080619-00-A
  21. With an assistant inside the vehicle, close the liftgate.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Safety glasses
  22. Connect the T-handles to the wire.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • T-Handles - 1078806-00-A
  23. Apply masking tape around the backlight glass to prevent damage to the body during glass removal.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Masking tape
  24. Use the T-handles to cut the urethane that attaches the backlight glass to the liftgate.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Plastic trim tool
    • Safety glasses
    • T-Handles - 1078806-00-A
  25. With assistance, attach the suction cups to the backlight glass, and then carefully remove the glass from the liftgate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the suction cups on each side of the glass.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Double suction cup handle - 1080599-00-A
    • Portable bench - 1054720-00-A
  26. Use IPA wipes to clean and remove any remaining adhesive from the backlight glass frame.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • IPA wipes
    • Winged scraper set - 1080601-00-A
  27. Remove any remaining masking tape from the liftgate.

Install

  1. With assistance, remove the new backlight glass from the packaging, and then place the glass on a portable bench.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Portable bench - 1054720-00-A
    • Retractable blade knife
  2. Use IPA wipes to clean the urethane path on the backlight glass. Allow 1 minute dry time.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • IPA wipes
  3. Apply primer on the backlight glass.
  4. Prepare the caulking gun and urethane.
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    Note
    Urethane opening must be 8mm wide and 14mm tall.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Caulk and adhesive gun - 1080593-00-A
    • Retractable blade knife
    • Tape measure metric/inch
  5. Apply the urethane on the backlight glass following the primer path.
  6. With assistance, attach the suction cups to the backlight glass, and then carefully install the glass on the liftgate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the suction cups on each side of the glass.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Double suction cup handle - 1080599-00-A
    • Portable bench - 1054720-00-A
  7. Check gap and flush measurements and adjust as necessary.
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    Note
    Refer to CVIS for current gap and flush specifications.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Gap and flush tool
  8. Apply masking tape on the backlight glass and the liftgate while the urethane cures.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Masking tape
  9. Remove the suction cups from the backlight glass.
  10. Position the passive spoiler assembly on the vehicle, and then install the screws (x4) that attach the spoiler to the vehicle.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 6 in extension
    • Flex head ratchet/flex head torque wrench
    • Ratchet/torque wrench
    • Torx T30 socket
  11. Install the spoiler applique. See Applique - Spoiler (Remove and Install).
  12. Open the liftgate.
  13. Connect the LH and RH defroster grid and antenna connectors (x4).
  14. Connect the CHMSL lamp harness connector, and then install the clip that attaches the connector to the liftgate.
  15. Install the RH active spoiler catch basin cover. See Cover - Catch Basin - Active Spoiler - LH (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the harness on the catch basin cover.
  16. Install the LH active spoiler catch basin cover. See Cover - Catch Basin - Active Spoiler - LH (Remove and Replace).
  17. Install the liftgate upper trim. See Trim - Upper - Liftgate (Remove and Replace).
  18. Install the liftgate speaker grille. See Grille - Speaker - Liftgate (Remove and Replace).
  19. Install the lower liftgate trim. See Trim - Liftgate - Lower (Remove and Replace).
  20. Close the liftgate.
  21. Raise the LH front window.
  22. Close the LH front door.