2026-05-08

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

Correction code 10106702

  • 2026-05-08: Added steps about how to properly identify and order the replacement glass, and steps about door bumper stops and front/rear brackets.

Removal

  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. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  3. Remove HEPA filter. See Filter - HEPA (Remove and Replace).
  4. Remove the LH rear upper door trim. See Panel - Door Trim - Rear - Upper - LH (Remove and Replace).
  5. Remove the LH rear door trim panel. See Panel - Door Trim - Rear - LH (Remove and Install).
  6. Remove the LH falcon door upper glass. See Door Glass - Rear - Upper - LH (Remove and Replace).
  7. Open the LH rear door.
  8. Support the rear door.
    Informational PurposesAn informational icon, calling your attention
    Note
    May need assist to open.
  9. Disconnect the LV battery power. See Disconnect 12V Power.
  10. Release the clips (x3) that attach the harness connectors to the closeout panel.
  11. Remove the ground strap from the lower falcon door and disconnect the door harness from the close out panel harness (1x bolt, 3 connectors).
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  12. Remove the lower falcon door harness clips (x5).
  13. Mark the position of the lower falcon door to the upper falcon door assembly.
  14. Remove the LH rear lower falcon door. See Door Assembly - Rear Lower - LH (Remove and Install).
  15. Remove the LH rear upper falcon door. See Door Assembly - Rear Upper - LH (Remove and Install).
  16. Remove the front secondary strut with bracket from the upper falcon door (1x C-clips,2x harness clips, 3x bolts).
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  17. Remove the rear secondary strut with bracket from the upper falcon door (1x C-clips,2x harness clips, 3x bolts).
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  18. Remove the fasteners (x6) that hold the LH front and rear brackets and remove from the upper falcon door.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  19. With assistance, remove the front and rear secondary hinge assemblies with the clamp brackets (6x bolts).
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP16
  20. Remove the front and rear bump stops (6x fasteners).
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark or remember the position of the bump stop to aid the installation process.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Ratcheting Combination wrench Flex head 10mm
    • Torx T30 socket

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 wipes to clean the NVH seal area of the new upper falcon door, and allow 1 minute to dry.
  2. Apply adhesive promoter to the NVH seal area of the new upper falcon door, and allow 1 minute to dry.
  3. Install new upper falcon door NVH seal to the new upper falcon door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use roller to press the seal in place.
  4. Install the LH front and rear upper falcon door bump stops (6x fasteners).
    8 Nm (5.9 lbs-ft)
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The 10mm bolts (x4) are 8Nm; the T30 screws (x2) are 5Nm.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Ratcheting Combination wrench Flex head 10mm
    • Torx T30 socket
  5. Install the front and rear secondary hinge assemblies with the clamp brackets (6x bolts).
    32 Nm (23.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP16
  6. Install the front and rear secondary struts with brackets to the upper falcon door (2x C-clips, 4x harness clips, 6x bolts).
    12 Nm (8.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP16
  7. Install the LH rear upper falcon door. See Door Assembly - Rear Upper - LH (Remove and Install).
    Informational PurposesAn informational icon, calling your attention
    Note
    Only install the bolts that secure the upper falcon door for now. Install other components after checking the gap and flush.
  8. Install the LH rear lower falcon door. See Door Assembly - Rear Lower - LH (Remove and Install).
  9. Close the LH rear door and window.
  10. Check the gap and flush of the LH falcon door according to specification, and adjust as needed.
  11. Adjust door as close to the 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 adjusted 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
  12. Install the other components of the LH rear upper falcon door. See Door Assembly - Rear Upper - LH (Remove and Install).
  13. Install the lower falcon door harness clips (x5).
  14. Install the ground strap from lower falcon door and connect door harness to close out panel harness (1x bolt, 3 connectors).
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  15. Secure the clips (x3) that attach the harness connectors to the closeout panel.
  16. Connect the LV battery power. See Disconnect 12V Power.
  17. Remove the door support stand.
  18. Calibrate the falcon doors using MCU.
  19. Use the manual over ride button to open and close the LH falcon wing door and test the door function.
  20. Check the gap and flush of the LH falcon door according to specification, and adjust as needed.
  21. Determine the correct replacement part number to order for the rear upper door glass.
    Informational PurposesAn informational icon, calling your attention
    Note

    For narrow stud pattern doors, -S2- style coded glass is needed. For wide stud pattern (current production) doors, -00- style coded glass is needed.

    “Dark Black” tint is used on the -S2- style coded glass on pedigree -K and later. Prior to -K, -S2- style coded glass used a discontinued “Light Black” tint.

    Check the Parts Manual for newer part revisions or updates. Order the latest part numbers where * appears, always confirm narrow stud pattern door service history when preordering glass.

  22. Install the LH falcon door upper glass. See Door Glass - Rear - Upper - LH (Remove and Replace).
  23. Install the LH rear door trim panel. See Panel - Door Trim - Rear - LH (Remove and Install).
  24. Install the LH rear upper door trim. See Panel - Door Trim - Rear - Upper - LH (Remove and Replace).
  25. Install HEPA filter. See Filter - HEPA (Remove and Replace).
  26. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).