11/12/2024 10:08:06

Glass - Roof - Fixed (Remove and Replace)

Correction code 10205002 1.98 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 wearing proper PPE when performing the below procedure.

2024-12-11: Added new caution about Pre-Installation Glass Inspection service requirements.
2024-07-08: Added step and note to apply masking tape and check adhesive drive-away time before driving the vehicle.

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.

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.

Figure 1. Model 3 shown; Model Y similar

Remove

Open all the doors and lower all the windows.
Open the liftgate.
Apply masking tape to protect the paint on the vehicle.
Install the headliner protector between the headliner and the fixed glass above the driver rear seat.
Secure the line to the starter tool and push the tool through the urethane at the LH rear corner of the fixed roof glass assembly.

CAUTION
Be careful not to damage the headliner assembly and exterior paint.
Pull the nylon string through.

Note
Make sure to pull enough string through to wrap around the circumference of the glass.
Route the nylon string around the glass, lifting and placing under the seals.

CAUTION
Be careful not to damage the seal for windshield during routing.
Insert the nylon string back though the wire starter, and then retract back into the vehicle.
Remove the nylon string from the starter tool.
Attach cutting tools to the fixed glass, and then pump the cutting tool to secure it to the glass.

Note
Make sure the suction is sufficient by checking the red ring is no longer visible.
Use one end of the nylon as an anchor point in the vehicle using the suction cup.
Route nylon through the cutting tool and turn to take up the slack in the nylon.
Use a drill to cut the urethane around the glass. Move the headliner protector with the line as it cuts.

CAUTION
Take precaution to make sure the line goes above the datums and the roof brackets. If the line gets caught on the roof bracket then the line will break.

Note
Use the headliner protector or a trim tool to apply upward pressure to the line as it cuts.

Note
If the line gets stuck, try to pull it backwards in order release it from under the metal roof bracket or change the positions of the anchor and cutting tool.
Remove the cutting tools from the glass.
With assistance, attach suction cups (x4) to each corner of the fixed roof glass.
With an assistant, remove the fixed roof glass from the vehicle.

Note
Discard the glass per local regulations.
Use a scraper to remove old urethane from the body, and then wipe the body to clean the surfaces with isopropyl alcohol wipes.

Note
Make sure the remaining urethane is 1 mm or less in thickness.

Warning
Make sure to wear proper PPE, including cut-resistant gloves, during this step.
Remove any broken datums and replace any damaged body plugs.

Install

Clean the urethane path on the vehicle with an isopropyl alcohol wipes.

Note
Allow 1 minute of dry time.
Attach suction cups (x4) to each corner of the new fixed roof glass.
With assistance, position new roof glass onto the vehicle for a dry fit.
Make sure gap and flushness is within acceptable limits.

Note
If the glass is too high, it may be necessary to trim or remove net pads.
With assistance, remove the roof glass and set it upside-down onto a work stand.
Remove the protective tape from the body.
Clean the glass mating surfaces with isopropyl alcohol.

Note
Allow 1 minute of dry time.
Apply urethane primer to the vehicle body along the urethane path and in areas that were damaged during removal of the fixed roof glass.

Note
Primer should go around the inside of the roof bracket.

Note
Allow the primer to dry for at least 1 minute.
Apply urethane to the body following the original path.

Note
Make sure that the urethane bead has a triangular cross-section of approximate width 12.5 mm and height 20 mm.

Note
Urethane should go around the inside of the roof bracket.
With an assistant, install the new fixed roof glass onto the vehicle, but do not set it yet.

Note
Align the datums centered at the front and rear of the glass to the body.
Position a new seal at the front of the glass beneath the windshield seal.

Tip: Use a trim tool to properly seat the roof glass seal under the windshield seal.
Press the glass onto the body once it is in position.

Note
Use sandbags for the front if needed.
Check that gap and flushness is within specification and adjust if necessary.
Remove the suction cups from the roof glass.
Clean the glass.
Apply painter's tape to the glass to secure it into position.

Warning
Do not drive the vehicle until the adhesive manufacturer’s recommended minimum drive-away time has passed. 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.
Raise all the windows and close all the doors.