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Home >> Tesla >> 2020 >> Model X Performance >> Repair and Diagnosis (Single Page) >> Body & Frame >> Exterior Body Panels >> Body -- Model X >> Body Panels >> Door Assembly - Rear Upper - LH - Remove And Replace >> Remove And Replace

Remove And Replace

  1. Measure the gap and flush of LH falcon door according to specification
    NOTE: Record that data and use it as a base line when installing the new door
    G15199326Courtesy of TESLA, INC.
    G15199327Courtesy of TESLA, INC.
    G15199328Courtesy of TESLA, INC.
    G15199329Courtesy of TESLA, INC.
  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
    NOTE: 9x V-clips, Replace any damaged or missing V-clips, Take care not to damage door trim panel during removal
    G15199330Courtesy of TESLA, INC.
    G15199331Courtesy of TESLA, INC.
  8. Remove LH upper falcon door trim
    NOTE: 17x clips, 1x connector may be present on early production vehicles
    G15199332Courtesy of TESLA, INC.
    G15199333Courtesy of TESLA, INC.
  9. Remove LH upper outer falcon door rear trim
    NOTE: 5x bolts, T25, 2.5 N.m, 4.0 N.m, 1x harness clip, Fastener count may vary
    G15199334Courtesy of TESLA, INC.
  10. Remove LH upper outer falcon door front trim
    NOTE: 5x bolts, T25, 2.5 N.m, 4.0 N.m, 1x harness clip, Fastener count may vary
    G15199335Courtesy of TESLA, INC.
  11. Remove LH upper outer falcon door middle trim
    NOTE: 7x bolts, T25, 3.0 N.m, 4.0 N.m, Fastener count may vary
    G15199336Courtesy of TESLA, INC.
  12. Remove LH upper gap hider trim
    NOTE: 4x clips
    G15199337Courtesy of TESLA, INC.
  13. Lower LH falcon door
    NOTE: May need to assist the door to close
  14. Remove LH falcon door upper glass
    NOTE: 10x nuts, 10 mm, 6 N.m, Recommend assistance
    G15199338Courtesy of TESLA, INC.
    G15199339Courtesy of TESLA, INC.
  15. Remove decorative trim panel
    NOTE: 8x clips, Push down 2 metal clips and slide rearward to release the trim
    G15199340Courtesy of TESLA, INC.
    G15199341Courtesy of TESLA, INC.
  16. Remove door panel bolts
    NOTE: 8x bolts, 10 mm, 6 N.m
    G15199342Courtesy of TESLA, INC.
  17. Remove LH rear door trim panel
    NOTE: 13x clips, 1x connector
    G15199343Courtesy of TESLA, INC.
    G15199344Courtesy of TESLA, INC.
  18. Open LH rear door
  19. Support the rear door
    NOTE: May need assist to open
    G15199345Courtesy of TESLA, INC.
  20. Open hood
    NOTE: Via center display > Controls > Front Trunk
  21. Power down vehicle using MCU
    NOTE: Via Controls > Safety > "Power off"
  22. Remove underhood aprons
    NOTE: 4x aprons
    G15199346Courtesy of TESLA, INC.
  23. Remove frunk carpet
    NOTE: 2x connectors
    G15199347Courtesy of TESLA, INC.
  24. Remove underhood storage unit
    NOTE: 10x bolts, 10 mm, 4 N.m, 10x bolts, 10 mm, 7 N.m
    G15199348Courtesy of TESLA, INC.
    G15199349Courtesy of TESLA, INC.
    G15199350Courtesy of TESLA, INC.
  25. Remove HEPA filter
    NOTE: Lift up from bottom and pull out
    G15199351Courtesy of TESLA, INC.
  26. Disconnect 12V negative terminal and First Responder Loop
    NOTE: 1x nut, 10 mm, 5 N.m, 1x connector, Wait at least 2 minutes before disconnecting modules or HV components
    G15199352Courtesy of TESLA, INC.
    G15199353Courtesy of TESLA, INC.
  27. Release clips securing harness connectors to closeout panel
    NOTE: 3x clips
    G15199354Courtesy of TESLA, INC.
  28. Remove the ground strap from lower falcon door and disconnect door harness from close out panel harness
    NOTE: 1x bolt, 10 mm, 9 N.m, 3 connectors
    G15199355Courtesy of TESLA, INC.
  29. Remove lower falcon door harness clips
    NOTE: 5x clips
    G15199356Courtesy of TESLA, INC.
  30. Mark the position of the lower falcon door to the upper falcon door assembly
    G15199357Courtesy of TESLA, INC.
  31. Remove the lower falcon door from vehicle
    NOTE: 4x bolts, 13 mm, 24 N.m, Recommend assistant to hold the lower falcon door.
    G15199358Courtesy of TESLA, INC.
    G15199359Courtesy of TESLA, INC.
  32. Disconnect both front and rear falcon door strut connectors
    NOTE: 4x connectors
    G15199360Courtesy of TESLA, INC.
  33. Remove the upper falcon door harness clips and route the harness to back of the falcon door
    NOTE: 7x clips, Protect the spine applique
    G15199361Courtesy of TESLA, INC.
    G15199362Courtesy of TESLA, INC.
  34. Remove the front primary strut from upper falcon door
    NOTE: 1x C-clip, 1x harness clip
    G15199363Courtesy of TESLA, INC.
  35. Remove the rear primary strut from upper falcon door
    NOTE: 1x C-clip
    G15199364Courtesy of TESLA, INC.
  36. Pull the upper falcon door lower to mark the hinges
    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.
    G15199365Courtesy of TESLA, INC.
    G15199366Courtesy of TESLA, INC.
  37. Remove the LH upper falcon door from vehicle
    NOTE: 4x 13 mm bolts, 24 N.m, Loosen bolts in closed position, Remove bolts in open position, Recommend assistance if necessary
    G15199367Courtesy of TESLA, INC.
    G15199368Courtesy of TESLA, INC.
  38. Lay LH rear door upper harness on top of vehicle
    NOTE: Use fender cover to protect spine and roof glass
    G15199369Courtesy of TESLA, INC.
  39. Remove the front secondary strut with bracket from the upper falcon door
    NOTE: 1x C-clips, 2x harness clips, 3x bolts, 10 mm, 12 N.m
    G15199370Courtesy of TESLA, INC.
    G15199371Courtesy of TESLA, INC.
    G15199372Courtesy of TESLA, INC.
    G15199373Courtesy of TESLA, INC.
  40. Remove the rear secondary strut with bracket from the upper falcon door
    NOTE: 1x C-clips, 2x harness clips, 3x bolts, 10 mm, 12 N.m
    G15199374Courtesy of TESLA, INC.
    G15199375Courtesy of TESLA, INC.
    G15199376Courtesy of TESLA, INC.
    G15199377Courtesy of TESLA, INC.
  41. Remove the front secondary hinge assembly with clamp bracket
    NOTE: 3x bolts, ET 18, 32 N.m, Recommend assistance if necessary
    G15199378Courtesy of TESLA, INC.
    G15199379Courtesy of TESLA, INC.
    G15199380Courtesy of TESLA, INC.
  42. Remove the rear secondary hinge assembly with clamp bracket
    NOTE: 3x bolts, ET 18, 32 N.m, Recommend assistance if necessary
    G15199381Courtesy of TESLA, INC.
    G15199382Courtesy of TESLA, INC.
    G15199383Courtesy of TESLA, INC.
  43. Remove LH front upper falcon door bumpstop assembly
    NOTE: 2x bolts, 10 mm, 8 N.m, 1x screw, T30, 5 N.m
    G15199384Courtesy of TESLA, INC.
    G15199385Courtesy of TESLA, INC.
    G15199386Courtesy of TESLA, INC.
    G15199387Courtesy of TESLA, INC.
    G15199388Courtesy of TESLA, INC.
    G15199389Courtesy of TESLA, INC.
  44. Remove LH rear upper falcon door bumpstop assembly
    NOTE: 2x bolts, 10 mm, 8 N.m, 1x screw, T30, 5 N.m
    G15199390Courtesy of TESLA, INC.
    G15199391Courtesy of TESLA, INC.
    G15199392Courtesy of TESLA, INC.
    G15199393Courtesy of TESLA, INC.
    G15199394Courtesy of TESLA, INC.
    G15199395Courtesy of TESLA, INC.
  45. Use IPA clean NVH seal area of the new upper falcon door
    NOTE: Allow 1 minute drying time
    G15199396Courtesy of TESLA, INC.
    G15199397Courtesy of TESLA, INC.
  46. Apply adhesive promoter to NVH seal area of the new upper falcon door
    NOTE: Allow 1 minute drying time
    G15199398Courtesy of TESLA, INC.
    G15199399Courtesy of TESLA, INC.
  47. Install new upper falcon door NVH seal to new upper falcon door
    NOTE: Use roller to press the seal in place
    G15199400Courtesy of TESLA, INC.
    G15199401Courtesy of TESLA, INC.
    G15199402Courtesy of TESLA, INC.
  48. Install LH front upper falcon door bumpstop assembly
    NOTE: 2x bolts, 10 mm, 8 N.m, 1x screw, T30, 5 N.m
    G15199403Courtesy of TESLA, INC.
    G15199404Courtesy of TESLA, INC.
    G15199405Courtesy of TESLA, INC.
    G15199406Courtesy of TESLA, INC.
    G15199407Courtesy of TESLA, INC.
    G15199408Courtesy of TESLA, INC.
  49. Install LH rear upper falcon door bumpstop assembly
    NOTE: 2x bolts, 10 mm, 8 N.m, 1x screw, T30, 5 N.m
    G15199409Courtesy of TESLA, INC.
    G15199410Courtesy of TESLA, INC.
    G15199411Courtesy of TESLA, INC.
    G15199412Courtesy of TESLA, INC.
    G15199413Courtesy of TESLA, INC.
    G15199414Courtesy of TESLA, INC.
  50. Install the rear secondary hinge assembly with bracket
    NOTE: 3x bolts, ET 18, 32 N.m
    G15199415Courtesy of TESLA, INC.
    G15199416Courtesy of TESLA, INC.
    G15199417Courtesy of TESLA, INC.
  51. Install the front secondary hinge assembly with bracket
    NOTE: 3x bolts, ET 18, 32 N.m
    G15199418Courtesy of TESLA, INC.
    G15199419Courtesy of TESLA, INC.
    G15199420Courtesy of TESLA, INC.
  52. Install the rear secondary strut with bracket from the upper falcon door
    NOTE: 1x C-clips, 2x harness clips, 3x bolts, 10 mm, 12 N.m
    G15199421Courtesy of TESLA, INC.
    G15199422Courtesy of TESLA, INC.
    G15199423Courtesy of TESLA, INC.
    G15199424Courtesy of TESLA, INC.
  53. Install the front secondary strut with bracket from the upper falcon door
    NOTE: 1x C-clips, 2x harness clips, 2x bolts, 10 mm, 12 N.m
    G15199425Courtesy of TESLA, INC.
    G15199426Courtesy of TESLA, INC.
    G15199427Courtesy of TESLA, INC.
    G15199428Courtesy of TESLA, INC.
  54. Install the LH upper falcon door and hand tighten bolts
    NOTE: 4x bolts, 13 mm, 24 N.m, Recommend assistance if necessary
    G15199429Courtesy of TESLA, INC.
  55. Pull the upper falcon door lower and make sure the upper falcon door is aligned and centered before tightening
    NOTE: 4x bolts, 13 mm, 24 N.m, 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.
    G15199430Courtesy of TESLA, INC.
    G15199431Courtesy of TESLA, INC.
  56. Install the rear primary strut to upper falcon door
    NOTE: 1x C-clip, 1x harness clip, Door may need to be lifted to align strut, Recommend assistance
    G15199432Courtesy of TESLA, INC.
  57. Install the front primary strut to upper falcon door
    NOTE: 1x C-clip, 1x harness clip, Door may need to be lifted to align strut, Recommend assistance
    G15199433Courtesy of TESLA, INC.
  58. Install the upper falcon door harness
    NOTE: 7x clips, Replace any broken clips
    G15199434Courtesy of TESLA, INC.
    G15199435Courtesy of TESLA, INC.
  59. Connect both front and rear falcon door strut connectors and secure
    NOTE: 4x connectors, 2 clips
    G15199436Courtesy of TESLA, INC.
  60. Install the lower falcon door to vehicle
    NOTE: 4x bolts, 13 mm, 24 N.m, Recommend assistant to hold the lower falcon door, Ensure the lower falcon door hinges align with marked position before tightening bolts
    G15199437Courtesy of TESLA, INC.
    G15199438Courtesy of TESLA, INC.
  61. Install lower falcon door harness clips
    NOTE: 5x clips
    G15199439Courtesy of TESLA, INC.
  62. Install the ground strap from lower falcon door and connect door harness to close out panel harness
    NOTE: 1x bolt, 10 mm, 9 N.m, 3 connectors
    G15199440Courtesy of TESLA, INC.
  63. Secure clips securing harness connectors to closeout panel
    NOTE: 3x clips
    G15199441Courtesy of TESLA, INC.
  64. Connect first responder loop and then 12V negative terminal
    NOTE: 1x connector, 1x nut, 10 mm, 5 N.m
    G15199442Courtesy of TESLA, INC.
    G15199443Courtesy of TESLA, INC.
  65. Remove door support stand
    G15199444Courtesy of TESLA, INC.
  66. Calibrate falcon doors using MCU
    NOTE: Required after 12V and FRL disconnect
    G15199445Courtesy of TESLA, INC.
  67. Close LH rear door and window
  68. Check the gap and flush of LH falcon door according to specification
    NOTE: Adjust as needed
    G15199446Courtesy of TESLA, INC.
    G15199447Courtesy of TESLA, INC.
    G15199448Courtesy of TESLA, INC.
    G15199449Courtesy of TESLA, INC.
  69. Adjust door as close to specification as possible if necessary
    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, 32 N.m, 4x bolts, 13 mm, 24 N.m
    G15199450Courtesy of TESLA, INC.
    G15199451Courtesy of TESLA, INC.
  70. Install LH falcon door upper glass
    NOTE: 10x nuts, 10 mm, 6 N.m, Recommend assistance
    G15199452Courtesy of TESLA, INC.
    G15199453Courtesy of TESLA, INC.
  71. Open LH rear door
  72. Install LH upper gap hider trim
    NOTE: 4x clips
    G15199454Courtesy of TESLA, INC.
  73. Install LH upper outer falcon door middle trim
    NOTE: 7x bolts, T25, 3.0 N.m, 4.0 N.m, Fastener count may vary
    G15199455Courtesy of TESLA, INC.
    G15199456Courtesy of TESLA, INC.
    G15199457Courtesy of TESLA, INC.
  74. Install LH upper outer falcon door front trim
    NOTE: 5x bolts, T25, 2.5 N.m, 4.0 N.m, 1x harness clip, Fastener count may vary
    G15199458Courtesy of TESLA, INC.
    G15199459Courtesy of TESLA, INC.
    G15199460Courtesy of TESLA, INC.
  75. Install LH upper outer falcon door rear trim
    NOTE: 5x bolts, T25, 2.5 N.m, 4.0 N.m, 1x harness clip, Fastener count may vary
    G15199461Courtesy of TESLA, INC.
    G15199462Courtesy of TESLA, INC.
    G15199463Courtesy of TESLA, INC.
  76. Replace LH rear door trim panel clips
    NOTE: 13x clips
    G15199464Courtesy of TESLA, INC.
  77. Install LH rear door trim panel
    NOTE: 13x clips, 1x connector
    G15199465Courtesy of TESLA, INC.
    G15199466Courtesy of TESLA, INC.
  78. Install bolts securing LH rear door trim panel to door
    NOTE: 8x bolts, 10 mm, 6 N.m
    G15199467Courtesy of TESLA, INC.
  79. Install LH rear door decor trim
    NOTE: 8x clips
    G15199468Courtesy of TESLA, INC.
    G15199469Courtesy of TESLA, INC.
    G15199470Courtesy of TESLA, INC.
  80. Install LH upper falcon door trim
    NOTE: 17x clips, Align strut cover first, 1x connector may be present on early production vehicles
    G15199471Courtesy of TESLA, INC.
    G15199472Courtesy of TESLA, INC.
  81. Install LH falcon door lower garnish
    NOTE: 9x V-clips, 1x guide tab
    G15199473Courtesy of TESLA, INC.
  82. Close LH Falcon door
  83. Install HEPA filter housing
    G15199474Courtesy of TESLA, INC.
  84. Install underhood storage unit
    NOTE: 10x bolts, 10 mm, 4 N.m, 10x bolts, 10 mm, 7 N.m
    Fig 1: Underhood Storage Unit Bolts With Torque Specification (1 Of 3)
    G15199475Courtesy of TESLA, INC.
    Fig 2: Underhood Storage Unit Bolts With Torque Specification (2 Of 3)
    G15199476Courtesy of TESLA, INC.
    Fig 3: Underhood Storage Unit Bolts With Torque Specification (3 Of 3)
    G15199477Courtesy of TESLA, INC.
  85. Install frunk carpet
    NOTE: 2x connectors
    G15199478Courtesy of TESLA, INC.
  86. Install under hood aprons
    NOTE: 4x aprons
    G15199479Courtesy of TESLA, INC.
  87. Close hood
  88. Move LH front seat to original position
  89. Raise LH rear window
  90. Raise LH front window
  91. Close LH front door
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