2024-05-30

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

Correction code 10106702

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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.

Removal

  1. Measure the gap and flush of LH falcon door according to specification
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    Note
    Record that data and use it as a base line when installing the new door
  2. Open LH front door
  3. Lower LH front window
  4. Lower LH rear window fully
  5. Move LH front seat forward
  6. Open LH falcon door
  7. Remove LH falcon door lower garnish
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    Note
    9x V-clips, Replace any damaged or missing V-clips, Take care not to damage door trim panel during removal
  8. Remove LH upper falcon door trim
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    Note
    17x clips, 1x connector may be present on early production vehicles
  9. Remove LH upper outer falcon door rear trim
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    Note
    5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
  10. Remove LH upper outer falcon door front trim
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    Note
    5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
  11. Remove LH upper outer falcon door middle trim
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    Note
    7x bolts, T25, 3.0 Nm, 4.0 Nm, Fastener count may vary
  12. Remove LH upper gap hider trim
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    Note
    4x clips
  13. Lower LH falcon door
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    Note
    May need to assist the door to close
  14. Remove LH falcon door upper glass
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    Note
    10x nuts, 10mm, 6 Nm, Recommend assistance
  15. Remove decorative trim panel
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    Note
    8x clips, Push down 2 metal clips and slide rearward to release the trim
  16. Remove door panel bolts
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    Note
    8x bolts, 10mm, 6 Nm
  17. Remove LH rear door trim panel
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    Note
    13x clips, 1x connector
  18. Open LH rear door
  19. Support the rear door
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    Note
    May need assist to open
  20. Open hood
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    Note
    Via center display > Controls > Front Trunk
  21. Power down vehicle using MCU
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    Note
    Via Controls > Safety > ''Power off"
  22. Remove underhood aprons
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    Note
    4x aprons
  23. Remove frunk carpet
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    Note
    2x connectors
  24. Remove underhood storage unit
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    Note
    10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
  25. Remove HEPA filter
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    Note
    Lift up from bottom and pull out
  26. Disconnect 12V negative terminal and First Responder Loop
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    Note
    1x nut, 10mm, 5 Nm, 1x connector, Wait at least 2 minutes before disconnecting modules or HV components
  27. Release clips securing harness connectors to closeout panel
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    Note
    3x clips
  28. Remove the ground strap from lower falcon door and disconnect door harness from close out panel harness
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    Note
    1x bolt, 10mm, 9 Nm, 3 connectors
  29. Remove lower falcon door harness clips
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    Note
    5x clips
  30. Mark the position of the lower falcon door to the upper falcon door assembly
  31. Remove the lower falcon door from vehicle
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    Note
    4x bolts, 13mm, 24 Nm, Recommend assistant to hold the lower falcon door.
  32. Disconnect both front and rear falcon door strut connectors
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    Note
    4x connectors
  33. Remove the upper falcon door harness clips and route the harness to back of the falcon door
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    Note
    7x clips,Protect the spine applique
  34. Remove the front primary strut from upper falcon door
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    Note
    1x C-clip, 1x harness clip
  35. Remove the rear primary strut from upper falcon door
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    Note
    1x C-clip
  36. Pull the upper falcon door lower to mark the hinges
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    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.
  37. Remove the LH upper falcon door from vehicle
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    Note
    4x 13mm bolts, 24Nm, Loosen bolts in closed position, Remove bolts in open position, Recommend assistance if necessary
  38. Lay LH rear door upper harness on top of vehicle
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    Note
    Use fender cover to protect spine and roof glass
  39. Remove the front secondary strut with bracket from the upper falcon door
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    Note
    1x C-clips,2x harness clips, 3x bolts, 10mm, 12Nm
  40. Remove the rear secondary strut with bracket from the upper falcon door
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    Note
    1x C-clips,2x harness clips, 3x bolts, 10mm, 12Nm
  41. Remove the front secondary hinge assembly with clamp bracket
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    Note
    3x bolts, EP 16, 32Nm, Recommend assistance if necessary
  42. Remove the rear secondary hinge assembly with clamp bracket
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    Note
    3x bolts, EP 16, 32Nm, Recommend assistance if necessary
  43. Remove LH front upper falcon door bumpstop assembly
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    Note
    2x bolts, 10mm, 8Nm, 1x screw, T30, 5Nm
  44. Remove LH rear upper falcon door bumpstop assembly
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    Note
    2x bolts, 10mm, 8Nm, 1x screw, T30, 5Nm

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. Use IPA clean NVH seal area of the new upper falcon door
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    Note
    Allow 1 minute drying time
  2. Apply adhesive promoter to NVH seal area of the new upper falcon door
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    Note
    Allow 1 minute drying time
  3. Install new upper falcon door NVH seal to new upper falcon door
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    Note
    Use roller to press the seal in place
  4. Install LH front upper falcon door bumpstop assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 8Nm, 1x screw, T30, 5Nm
  5. Install LH rear upper falcon door bumpstop assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 8Nm, 1x screw, T30, 5Nm
  6. Install the rear secondary hinge assembly with bracket
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    Note
    3x bolts, EP 16, 32 Nm
  7. Install the front secondary hinge assembly with bracket
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    Note
    3x bolts, EP 16, 32 Nm
  8. Install the rear secondary strut with bracket from the upper falcon door
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    Note
    1x C-clips,2x harness clips, 3x bolts, 10mm, 12Nm
  9. Install the front secondary strut with bracket from the upper falcon door
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    Note
    1x C-clips,2x harness clips, 2x bolts, 10mm, 12Nm
  10. Install the LH upper falcon door and hand tighten bolts
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    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
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    Note
    4x bolts, 13mm, 24 Nm, Use a rubber hammer to tap on the upper falcon door to center it, Recommend assistance,Caution: the upper falcon door hinges are spring loaded and it want to retract to falcon door open position.
  12. Install the rear primary strut to upper falcon door
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    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
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    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
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    Note
    7x clips, Replace any broken clips
  15. Connect both front and rear falcon door strut connectors and secure
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    Note
    4x connectors, 2 clips
  16. Install the lower falcon door to vehicle
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    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 lower falcon door harness clips
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    Note
    5x clips
  18. Install the ground strap from lower falcon door and connect door harness to close out panel harness
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    Note
    1x bolt, 10mm, 9 Nm, 3 connectors
  19. Secure clips securing harness connectors to closeout panel
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    Note
    3x clips
  20. Connect first responder loop and then 12V negative terminal
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    Note
    1x connector, 1x nut, 10mm, 5 Nm
  21. Remove door support stand
  22. Calibrate falcon doors using MCU
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    Note
    Required after 12V and FRL disconnect
  23. Close LH rear door and window
  24. Check the gap and flush of LH falcon door according to specification
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    Note
    Adjust as needed
  25. Adjust door as close to specification as possible if necessary
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    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, 32Nm, 4x bolts, 13mm, 24 Nm
  26. Install LH falcon door upper glass
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    Note
    10x nuts, 10mm, 6 Nm, Recommend assistance
  27. Open LH rear door
  28. Install LH upper gap hider trim
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    Note
    4x clips
  29. 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
  30. Install LH upper outer falcon door front trim
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
  31. Install LH upper outer falcon door rear trim
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    Note
    5x bolts, T25, 2.5 Nm, 4.0 Nm, 1x harness clip, Fastener count may vary
  32. Replace LH rear door trim panel clips
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    Note
    13x clips
  33. Install LH rear door trim panel
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    Note
    13x clips, 1x connector
  34. Install bolts securing LH rear door trim panel to door
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    Note
    8x bolts, 10mm, 6 Nm
  35. Install LH rear door decor trim
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    Note
    8x clips
  36. Install LH upper falcon door trim
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    Note
    17x clips, Align strut cover first, 1x connector may be present on early production vehicles
  37. Install LH falcon door lower garnish
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    Note
    9x V-clips, 1x guide tab
  38. Close LH Falcon door
  39. Install HEPA filter housing
  40. Install underhood storage unit
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    Note
    10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
  41. Install frunk carpet
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    Note
    2x connectors
  42. Install under hood aprons
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    Note
    4x aprons
  43. Close hood
  44. Move LH front seat to original position
  45. Raise LH rear window
  46. Raise LH front window
  47. Close LH front door