10/12/2024 15:13:20

Liftgate Glass (Remove and Replace)

Correction Code 10204002 - Active Spoiler, Correction Code 10204202 - Passive Spoiler

  • 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 all 4 windows. This prevents internal pressure from pushing out on the liftgate glass when it is installed.
  2. Open the LH and RH rear doors.
  3. Remove the liftgate speaker trim (refer to procedure).
  4. Close the liftgate, and then apply painter's tape to the panels that are adjacent to the liftgate glass.
  5. Remove the rear spoiler:
  6. Remove both stanchions from the vehicle:
  7. Vehicles with power liftgate only:
    1. Open the liftgate, and then disconnect the electrical harnesses for the LH, RH, and upper pinch sensors.
    2. Remove the fasteners that secure the LH and RH pinch sensors to the liftgate, then remove the LH and RH pinch sensors.
    3. Remove the upper pinch sensor.
  8. Disconnect the harnesses that attach to the glass on the LH and RH sides of the liftgate. Tape the harnesses to the liftgate so that they are out of the way when the glass is removed in a later step.
  9. Remove the upper liftgate glass seal.
  10. Use a glass-cutting blade to cut the LH and RH locator posts.
    Tip: Move the tool around to feel for the locations of the locator posts.
  11. Cut an appropriate length of square wire and insert the wire into the square wire cutting tool.
  12. Push the tool through the adhesive near the upper LH or RH corner. Pull the wire through and remove the tool.
  13. Connect the T-handles to the wire.
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    Note
    Use an assistant for the remainder of the removal steps to make removal easier.
  14. Cut out the liftgate glass. Use a flat tool to guide the wire around the locator post near the top of the glass.
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    Warning
    To avoid personal injury, eye protection must be worn when performing this operation.
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    CAUTION
    Take care not to damage component(s).
  15. Apply suction cups to the glass, and then remove the glass and place it on a stand.
  16. Use an adhesive scraper or razor blade to remove the excess adhesive from the liftgate, and then clean off any remaining adhesive with alcohol wipes.
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    Note
    Allow the alcohol to dry fully before installing new liftgate glass.
  17. Remove the old glass off the stand and place it into the appropriate bin for disposal.

Installation

  1. Check the LH and RH active spoiler lip seals for damage, and replace if necessary.
  2. Apply primer to the liftgate as directed by the adhesive manufacturer. Ensure that the primer fully covers any nicks or scratches in the paint.
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    Warning
    Check the expiration date of the primer and adhesive before use.
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    Note
    Check the primer and adhesive packaging for the appropriate working times for each product. Prepare the necessary tools and work environment so that the glass can be installed within the specified working times.
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    Note
    This procedure requires approximately 2 tubes of adhesive.
  3. Clean the etched area of the glass with alcohol wipes. Allow the alcohol to dry fully before continuing to the next step.
  4. Apply primer to the etched area of the glass as directed by the adhesive manufacturer.
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    Note
    Check the primer packaging for the appropriate wait time before applying adhesive.
  5. Cut the applicator tip on the adhesive tube in a triangular pattern: 8 mm wide, 14 mm tall.
  6. Apply the adhesive to the etched area of the liftgate glass.
  7. Apply suction cups to the glass, and then install the glass, starting from the top.
  8. Ensure that the gaps between the glass and the liftgate are even front to back and side to side. Evenly and progressively press the glass onto the spacers.
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    Note
    Clean off any excess adhesive that was extruded from the joint.
  9. Apply painter's tape to the glass to secure it into position.
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    Warning
    Do not drive the vehicle until the adhesive manufacturer’s recommended minimum drive-away time has passed. Dow Betaseal Express has a drive-away time of 1 hour minimum in temperatures of 0˚F (-18˚C) or warmer. If necessary, leave the tape applying pressure to the glass on the vehicle and advise the customer that they can remove it after 24 hours. Additionally, advise the customer that they should avoid high driving speeds and speed bumps for the next 24 hours.
  10. Reconnect all harness connections.
  11. Once the adhesive has cured, remove the painter's tape, and then have an assistant use a hose to spray water along the edges of the liftgate glass. Ensure that no water leaks into the interior.
  12. Reinstall all components that were removed for access.