2024-08-20

Door Assembly - Rear Lower - LH (Remove and Replace)

Correction code 10106502

  • 2024-08-20: Added information on required retrofit when fitting a 2021+ Model X door to a 2015-2020 Model X.
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Note
When fitting a 2021+ Model X door with part number 1028790-E0-K (FALCON DOOR LOWER, LEFT HAND) or 1028791-E0-K (FALCON DOOR LOWER, RIGHT HAND) or later revisions to a 2015-2020 Model X, first perform the retrofit procedure. See Door Assembly - Rear Lower LH (Retrofit).

Special tools required for this procedure:

Part Number Description
1832533-00-A Jig, Ultrasonic Sensor Install, MX
1080580-00-A Heat gun
1080603-00-A Infrared thermometer
1080978-00-A Force gauge
1080978-10-A 22 mm diameter tip for force gauge
1454796-00-A Window switch tool

Remove

  1. Measure the gap and flush of the LH rear door according to specification
    Informational PurposesAn informational icon, calling your attention
    Note
    Record the data and use it as a base line when installing the new door
  2. Open the LH front door and lower the window.
  3. Lower the LH rear window halfway.
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    Note
    Lowering the rear door glass halfway is required to gain access to the regulator nut later in this procedure.
  4. Move LH front seat forward
  5. Partially open the LH rear door.
  6. Remove the LH rear outer belt trim.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift and roll outward slowly and evenly starting from the rear edge. Be careful not to bend or damage components.
  7. Fully open the LH rear door.
  8. Remove the V-clips (x9) that attach the LH rear door lower garnish to the door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Replace any damaged or missing V-clips.
  9. Remove the clips (x17) that attach the LH upper rear door trim to the door.
    Informational PurposesAn informational icon, calling your attention
    Note
    A connector may be present on early production vehicles.
  10. Remove the LH rear door trim panel. See Panel - Door Trim - Rear - LH (Remove and Install).
  11. Remove the LH rear door inner belt seal.
  12. Disconnect 12V power. See Disconnect 12V Power.
  13. Remove the LH 2nd row curtain air bag. See Curtain Air Bag - 2nd Row - LH (Remove and Replace).
  14. Remove the screws (x10) that attach the closeout panel to the LH rear door.
  15. Disconnect the rear door ultrasonic sensor module.
  16. Disconnect the connectors (x2) from the LH rear door module.
  17. Release the clips (x7) that attach the lower rear door harnesses and connectors to LH closeout panel.
  18. Unclip and feed the door release cable through the LH closeout panel.
  19. Pull LH closeout panel away from the door and lift the window motor up to release.
  20. Remove the clip that attaches the window regulator harness to the LH closeout panel.
  21. Remove the bolt that attaches the ground wire to LH lower rear door.
  22. Release the harness clips (x5) from the LH lower rear door.
  23. Remove bolts (x4) that attach the speaker to the LH rear door, disconnect the speaker connector and then remove the speaker from the door.
  24. Loosen the nut that attaches the front of the LH rear window to the regulator.
    Informational PurposesAn informational icon, calling your attention
    Note
    The nut does not need to be fully removed. If required, power the vehicle back on and use the window switch tool to move the regulator for access to the nut.
  25. Partially close LH rear door
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    Note
    Do not engage latch
  26. Release the clip that attaches the rear of the LH rear window to regulator and remove glass from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance. Working from the outside of the vehicle, pull the front of the window towards the rear of the vehicle and then lift the window out from the door. Take caution do not damage any components
  27. Disconnect the LH rear door rear pinch sensor connector.
  28. Release the clip that attaches the LH rear door pinch sensor harness to the LH rear door.
  29. Remove the LH rear door lower bump stop.
  30. Remove the clips (x7) that attach the LH rear door rear pinch sensor.
  31. Remove the LH rear door rear pinch sensor.
  32. Disconnect the LH rear door front pinch sensor.
  33. Remove the clips (x7) that attach the LH rear door front pinch sensor.
  34. Remove LH rear door front pinch sensor
  35. Remove and discard the bolts (x5) that attach the LH rear door fixed glass.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully lift up airbag to access the lower screws. Release the fixed glass seal from the door assembly, Lift fixed glass from bottom edge and pull downwards to release upper edge from between upper cantrail and release seal from door assembly.
  36. Remove the screws (x2) that attach the LH rear door front applique.
  37. Release the clips (x2) that attach LH rear door front applique to the door, and then remove the front applique.
  38. Remove the screws (x7) that attach the LH rear upper bright molding.
  39. Disconnect the LH rear door window motor.
  40. Remove the nuts (x4) that attach the window motor/regulator assembly.
  41. Remove the window motor/regulator assembly from the LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not allow the washers to fall off the studs on the regulator. Push the regulator outboard so that the studs no longer protrude through the door shell, and then push the 2 beams of the regulator together and remove the window motor/regulator assembly from the LH rear door.
  42. Disconnect LH ultrasonic sensor and remove the harness from the rear door.
  43. Disconnect LH outer door handle carrier connector, and then release the harness clip from the door.
  44. Remove the nuts (x3) that attach the LH rear door outer door handle carrier.
  45. Remove the door handle assembly from the LH rear door/
    Informational PurposesAn informational icon, calling your attention
    Note
    Note the number and location of spacers, remove seal with the handle assembly.
  46. Disconnect the LH rear door close switch.
  47. Remove the LH rear door close switch.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hold on to the connector that is part of the lit button close switch while you turn the bezel counterclockwise. As the lit button close switch becomes loose, pull it out from the outside of the door
  48. Release the clip from the LH lower latch cover.
  49. Release the tabs (x2) that attach the door latch shroud, and then remove the LH rear door latch shroud.
  50. Disconnect the LH lower latch connector.
  51. Disconnect the LH cinching actuator connector.
  52. Remove and discard the screws (x2) that attach the door latch cover to the LH rear door.
  53. Remove the nuts (x3) that attach the LH cinching actuator.
  54. Remove the latch actuator shroud assembly from the LH rear door.
  55. Remove the screws (x2) that attach the LH rear door lower gap hider.
  56. Remove the LH lower rear door harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x connectors, 8x clips, 1x grommet
  57. Fully open the LH rear door, and then support the door.
  58. Mark the position of the LH lower rear door to the upper rear door assembly.
  59. Remove the bolts (x4) that attach the LH lower rear door to the vehicle, and then remove the LH rear door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend an assistant to hold the lower rear door while removing the bolts.
  60. Remove the front screws (x2) of the LH cantrail seal.
  61. Remove the rear screws (x2) of the LH cantrail seal.
  62. Remove the nuts (x7) that attach the LH cantrail seal.
  63. Remove the LH cantrail seal.

Installation

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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. Clean the area of the new LH lower rear door inner panel where butyl patches need to be applied with IPA wipes.
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    Note
    Allow 1 minute to dry.
  2. Apply butyl patches to LH lower rear door inner panel
  3. Clean the area of the new LH lower rear door outer panel where butyl patches need to be applied with IPA wipes.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute to dry.
  4. Apply butyl patches to LH lower rear door outer panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    Press firmly in the center of the butyl patch and smooth to the edges to avoid water leaks.
  5. Apply support foam to the butyl patch sticky side on the lower outer B-pillar and lower outer C-pillar of the LH lower rear door.
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    Note
    Cut to length
  6. Install the nuts (x7) that attach the LH cantrail seal starting from the back and working your way forward (torque 8 Nm).
  7. Install the rear screws (x2) that attach the LH cantrail seal (torque 3.5 Nm).
  8. Install the front screws (x2) that attach the LH cantrail seal (torque 3.5 Nm).
  9. Use IPA wipes to clean the LH lower rear door inner upper panel area where the seal for the NVH extrusion will be applied.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute to dry
  10. Install a new seal for the NVH extrusion at the top of door.
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    Note
    Apply adhesive promoter to the area and allow 1 minute drying time. Remove double sided tape and use a roller to press the seal in place. Center seal approximately 57 mm from the rear of cantrail seal and 52 mm from the front of the cantrail seal.
  11. Position the LH lower rear door to the vehicle, and then install the bolts (x4) that attach the door to vehicle (torque 24 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistant to hold the lower rear door. Make sure that the lower rear door hinges align with the position marks before tightening the bolts.
  12. Remove the door support stand.
  13. Partially close LH rear door.
  14. Install the LH lower rear door harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x connectors, 8x clips, 1x grommet. Feed interior connections through the opening and make sure that the grommet with the harness is pointing upwards for proper alignment.
  15. Install the screws (x2) that attach the LH rear door lower gap hider (toque 4 Nm).
  16. Position the latch actuator shroud assembly into the LH rear door.
  17. Install the nuts (x2) that attach the LH cinching actuator (torque 3 Nm).
  18. Install new screws (x2) that attach the door latch cover to LH Falcon door (torque 22 Nm).
  19. Connect LH cinching actuator connector.
  20. Connect the LH lower latch connector.
  21. Install the LH rear door latch shroud.
  22. Install the clip to the LH lower latch cover
  23. Install the LH rear door close switch.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate bezel clockwise to secure.
  24. Connect the LH rear door close switch connector.
  25. Position the door handle assembly to the LH rear door, and then install the nuts (x3) that attach the door handle assembly to the door (torque 9 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install same number of spacers at the original location as on the old door. Install seal with handle assembly, and then hand tighten the nuts.
  26. Torque the LH rear door outer door handle carrier nuts (toque 9 Nm)
  27. Connect the LH outer door handle carrier connector, and then install the harness clip.
  28. Install the LH rear door ultrasonic sensor carrier. See Carrier - Sensor - Ultrasonic - Rear Door - LH (Remove and Replace).
  29. Peel off the adhesive from the new sensor. Use a heat gun and infrared thermometer to heat sensor prior to application to the specified temperature.
    Informational PurposesAn informational icon, calling your attention
    Note
    Sensor must be between 40º - 50º C (104 - 122º F) prior to installation.
  30. Install the sensor onto the LH rear door ultrasonic sensor carrier.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the sensor does not touch the carrier.
  31. Use force gauge to press the sensor into the carrier.
    Informational PurposesAn informational icon, calling your attention
    Note
    Attach the 22 mm tip to the force gauge. Press with a force of 50N for 10 seconds.
  32. Install spacer, spring, and cap to secure the ultrasonic sensor.
  33. Connect the ultrasonic sensor connector, and then attach the harness clip to the ultrasonic sensor carrier.
  34. Attach the harness clip of the LH ultrasonic sensor harness to the rear door.
  35. Position the window motor/regulator assembly into the LH rear door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push the two beams together and ensure the studs protrude through the door shell. Do not allow the washers to fall off the studs on the regulator.
  36. Install the nuts (x4) that attach the window motor/regulator assembly to the door (torque 10 Nm).
  37. Connect the LH rear window motor connector.
  38. Install the screws (x7) that attach the LH rear upper bright molding (torque 3 Nm).
  39. Install the LH rear door front applique.
  40. Install the screw that attach the LH rear door front applique to the door (torque 3 Nm).
  41. Use IPA wipes to clean the LH cladding mount surface.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute to dry.
  42. Install the LH rear door cladding assembly.
  43. Install a new LH rear wheel arch door cladding and wet out the double sided tape.
  44. Apply P-80 Emulsion Grease onto the seals attached to LH rear door fixed glass for easier installation.
  45. Install the LH rear door fixed glass assembly.
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    Note
    5x patched screws, T25, 3.5 Nm. Install new patched bolts. Carefully lift up the airbag to access the lower screws, Place upper edge of fixed glass assembly in between cantrail seal. Position fixed glass to lineup with the rivet nuts, and then insert and secure the fixed glass seal onto door assembly.
  46. Install the LH rear door front pinch sensor.
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    Note
    1x grommet. Route the front rear door pinch sensor harness through the hole and secure the grommet.
  47. Push the clips that attach LH rear door front pinch sensor in place.
  48. Connect the LH rear door front pinch sensor connector.
  49. Use IPA wipes to clean the area on the LH rear door where the pinch sensor is stuck with 3M double sided tape
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute to dry
  50. Remove any adhesive residue from the LH rear pinch sensor carrier.
  51. Use IPA wipes to clean the top inner surface of the LH rear pinch sensor carrier and the LH rear door mating area.
  52. Apply adhesive promoter to the top inner surface of the pinch sensor carrier where double sided tape is to be applied.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute to dry.
  53. Cut a section of double sided tape to 145 mm in length.
    Informational PurposesAn informational icon, calling your attention
    Note
    3M RT8016 tape or equivalent
  54. Apply double sided tape to the LH rear pinch sensor carrier.
    Informational PurposesAn informational icon, calling your attention
    Note
    3 mm from opening for push clip, 4 mm from edge of pinch sensor panel, and at least 15 mm from cutout at top of pinch sensor carrier.
  55. Remove adhesive backing and position the reworked LH pinch sensor carrier onto the LH rear door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the 7 clip holes in the carrier with the 7 clip holes in LH rear door.
  56. Install the clips (x7) that attach the LH rear door rear pinch sensor.
  57. Use a silicone seam roller to wet-out the adhesive tape at the top edge of the LH pinch sensor carrier to the LH rear door.
  58. Install the LH rear door lower bump stop.
  59. Install the clip that attaches the LH rear door pinch sensor harness to LH rear door.
  60. Connect the LH rear door rear pinch sensor connector.
  61. Install the LH rear window glass into the vehicle and seat it onto the regulator.
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    Note
    1x clip. Recommend assistance. Carefully feed window glass into door and seat it into the rear clip and forward bracket.
  62. Make sure that the LH rear window glass fits correctly, and hen tighten the nut that attaches the front of the window to the regulator (torque 9 Nm).
  63. Connect the LH rear door speaker.
  64. Install the bolts (x4) that attach the LH rear door speaker (torque 4 Nm).
  65. Install the clips (x5) that attach the harness to LH lower rear door.
  66. Install the bolt that attaches the ground wire to the LH lower rear door (torque 10 Nm).
  67. Install the clip that attaches the LH rear window regulator harness to the door.
  68. Install the release cable through the LH closeout panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    If needed, lubricate the cable grommet to ease installation.
  69. Attach the LH window motor onto the back of the closeout panel.
  70. Install the screws (x3) that attach the window motor to the LH closeout panel (torque 1.8 Nm).
  71. Install the screws (x10) that attach the closeout panel to the door (torque 1.8 Nm).
  72. Install the clips (x7) that attach the harness and connectors to LH closeout panel.
  73. Connect the LH rear door module connectors (x2).
  74. Connect the rear door ultrasonic sensor module connector.
  75. Install the clips (x4) that attach the LH 2nd row curtain air bag onto the LH rear door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift the air bag straight up to expose the fir tree clips. Make sure that the fir tree clips fully seated.
  76. Install the bolts (x6) that attach the LH 2nd row curtain air bag (torque 7 Nm).
  77. Connect the LH 2nd row curtain air bag connector.
  78. Install the LH rear door inner belt seal.
  79. Connect 12V power. See Disconnect 12V Power
  80. Calibrate the rear doors from the touchscreen.
  81. Install the LH rear door outer belt trim.
  82. Test the window function and window fitment, adjust as required.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to CVIS for latest specifications. See Model X Exterior Gap and Flush Interface Deviations.
  83. Partially open LH rear door.
  84. Install the LH rear door trim panel and the decorative trim panel. See Panel - Door Trim - Rear - LH (Remove and Install).
  85. Install the LH upper rear door trim. See Panel - Door Trim - Rear - Upper - LH (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    A connector may be present on early production vehicles.
  86. Install the LH rear door lower garnish. See Garnish - Door Trim - LH - Rear - Lower (Remove and Replace)
  87. Close the LH rear door.
  88. If necessary, adjust the lower rear door bump stop.
  89. Measure the gap and flush of LH rear door according to specification.
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    Note
    Adjust the door as necessary
  90. Install the HEPA filter.
  91. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).