- 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
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- Open LH front door
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- Lower both LH side windows
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- Move LH front seat forward
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- Open LH falcon wing door
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- Remove LH falcon door lower garnish
NOTE:
9x V-clips, Replace any damaged or missing clips, Take care not to damage door trim panel during removal
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- Remove LH upper falcon door trim
NOTE:
17x clips, 1x connector may be present on early production vehicles
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- Remove LH falcon rear upper bracket
NOTE:
5x bolts, T25, 2.5 N.m, 4.0 N.m, 1x harness clip, Fastener count may vary
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- Remove LH falcon front upper bracket
NOTE:
5x bolts, T25, 2.5 N.m, 4.0 N.m, 1x harness clip
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- Remove LH upper outer falcon door middle trim
NOTE:
7x bolts, T25, 3.0 N.m, 4.0 N.m, Fastener count may vary
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- Remove LH upper gap hider trim
NOTE:
4x clips
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- Lower LH falcon door
NOTE:
May need to assist the door to close
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- Remove LH falcon door upper glass
NOTE:
10x nuts, 10 mm, 6 N.m, Recommend assistance
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- Remove LH rear decor trim panel
NOTE:
7x clips, 2x connectors
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- Remove bolts securing LH rear door panel to door
NOTE:
8x bolts, 10 mm, 6 N.m
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- Remove LH rear door trim panel
NOTE:
13x clips, 2x connectors
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- Open LH falcon wing door
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- Support the rear door
NOTE:
May need assist to open
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- Open hood
NOTE:
Via center display > Controls > Frunk Open
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- Remove rear underhood apron
NOTE:
11x clips, 2x datums
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- Power off vehicle via center display
NOTE:
Controls > Safety & Security > Power Off
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- Disconnect LV battery connector and First Responder Loop
NOTE:
2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL
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- Release clips securing harness connectors to closeout panel
NOTE:
3x clips
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- Disconnect connectors for upper harness
NOTE:
2x locking connectors, 1x connector
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- Remove bolt securing ground to LH lower falcon door
NOTE:
1x bolt, 10 mm, 10 N.m
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- Remove clips securing harness to LH lower falcon door
NOTE:
5x clips
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- Mark the position of the lower falcon door to the upper falcon door assembly
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- Remove the lower falcon door from vehicle
NOTE:
4x bolts, 13 mm, 24 N.m, Recommend assistant to hold the lower falcon door.
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- Disconnect both front and rear falcon door strut connectors
NOTE:
4x connectors
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- Remove the upper falcon door harness clips and route the harness to back of the falcon door
NOTE:
7x clips, Protect the spine applique
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- Remove the front primary strut from upper falcon door
NOTE:
1x C-clip, 1x harness clip
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- Remove the rear primary strut from upper falcon door
NOTE:
1x C-clip, 1x harness clip
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- 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.
 Courtesy of TESLA, INC.
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- Remove the LH upper falcon door from vehicle
NOTE:
4 x 13 mm bolts, 24 N.m, Loosen bolts in closed position, Remove bolts in open position, Recommend assistance if necessary
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- Lay LH rear door upper harness on top of vehicle
NOTE:
Use fender cover to protect spine and roof glass
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- Remove front secondary strut with bracket from upper falcon door
NOTE:
1x C-clips, 2x harness clips, 3x bolts, 10 mm, 12 N.m
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- Remove rear secondary strut with bracket from upper falcon door
NOTE:
1x C-clips, 2x harness clips, 3x bolts, 10 mm, 12 N.m
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Remove front secondary hinge assembly with clamp bracket
NOTE:
3x bolts, E18, 32 N.m, Recommend assistance
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- Remove rear secondary hinge assembly with clamp bracket
NOTE:
3x bolts, E18, 32 N.m, Recommend assistance
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 Courtesy of TESLA, INC.
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- Remove LH front upper falcon door bump stop assembly
NOTE:
2x bolts, 10 mm, 8 N.m, 1x screw, T30, 5 N.m
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Remove LH rear upper falcon door bump stop assembly
NOTE:
2x bolts, 10 mm, 8 N.m, 1x screw, T30, 5 N.m
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Use IPA clean NVH seal area of the new upper falcon door
NOTE:
Allow 1 minute drying time
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 Courtesy of TESLA, INC.
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- Apply adhesive promoter to NVH seal area of the new upper falcon door
NOTE:
Allow 1 minute drying time
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 Courtesy of TESLA, INC.
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- Install new upper falcon door NVH seal to new upper falcon door
NOTE:
Use roller to press the seal in place
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Install LH front upper falcon door bump stop assembly
NOTE:
2x bolts, 10 mm, 8 N.m, 1x screw, T30, 5 N.m
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Install LH rear upper falcon door bump stop assembly
NOTE:
2x bolts, 10 mm, 8 N.m, 1x screw, T30, 5 N.m
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Install the rear secondary hinge assembly with bracket
NOTE:
3x bolts, E18, 32 N.m
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Install the front secondary hinge assembly with bracket
NOTE:
3x bolts, E18, 32 N.m
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 Courtesy of TESLA, INC.
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- Install rear secondary strut with bracket from upper falcon door
NOTE:
1x C-clips, 2x harness clips, 3x bolts, 10 mm, 12 N.m
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Install front secondary strut with bracket from upper falcon door
NOTE:
1x C-clips, 2x harness clips, 2x bolts, 10 mm, 12 N.m
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Install the LH upper falcon door and hand tighten bolts
NOTE:
4x bolts, 13 mm, 24 N.m, Recommend assistance if necessary
 Courtesy of TESLA, INC.
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- 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 position upper falcon door to previous marked location, Use caution as the falcon door hinges are spring loaded and will want to retract to falcon door open position, Recommend assistance
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- 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
 Courtesy of TESLA, INC.
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- 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
 Courtesy of TESLA, INC.
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- Install the upper falcon door harness
NOTE:
7x clips, Replace any broken clips
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 Courtesy of TESLA, INC.
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- Connect both front and rear falcon door strut connectors
NOTE:
4x connectors
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- 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
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Install clips securing harness to falcon door
NOTE:
4x clips
 Courtesy of TESLA, INC.
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- Install bolt securing ground to LH rear door
NOTE:
1x bolt, 10 mm, 10 N.m
 Courtesy of TESLA, INC.
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- Connect three connectors for upper harness
NOTE:
2x locking connectors, 1x connector
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- Connect First Responder Loop and LV battery connector
NOTE:
2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage upper locking tab when fully seated
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 Courtesy of TESLA, INC.
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- Install rear underhood apron
NOTE:
11x clips, 2x datums
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 Courtesy of TESLA, INC.
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- Close hood
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- Remove door support stand
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- Calibrate the rear doors.
NOTE:
If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate
to calibrate the rear doors.
- Check the gap and flush of LH falcon door according to specification
NOTE:
Adjust as needed
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- 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
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Install LH falcon door upper glass
NOTE:
10x nuts, 10 mm, 6 N.m, Recommend assistance
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 Courtesy of TESLA, INC.
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- Open LH falcon wing door
NOTE:
Adjust position as required
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- Install LH rear door trim panel
NOTE:
2x connectors, 13x clips, Install door trim starting from top and make sure the door trim tab is fitted correctly on the inner belt seal
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 Courtesy of TESLA, INC.
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- Install bolts securing LH rear door panel to door
NOTE:
8x bolts, 10 mm, 6 N.m
 Courtesy of TESLA, INC.
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- Install LH rear door decor trim panel
NOTE:
7x clips, 2x connectors, Take care not to damage door trim panel
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Install LH upper gap hider trim
NOTE:
4x clips
 Courtesy of TESLA, INC.
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- Install LH upper outer falcon door middle trim
NOTE:
7x bolts, T25, 3.0 N.m, 4.0 N.m, Fastener count may vary
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Install LH falcon front upper bracket
NOTE:
5x bolts, T25, 2.5 N.m, 4.0 N.m, 1x harness clip, Fastener count may vary
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Install LH falcon rear upper bracket
NOTE:
5x bolts, T25, 2.5 N.m, 4.0 N.m, 1x harness clip, Fastener count may vary
 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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 Courtesy of TESLA, INC.
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- Install LH upper falcon door trim
NOTE:
17x clips, Align strut cover first, 1x connector may be present on early production vehicles
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 Courtesy of TESLA, INC.
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- Install LH falcon door lower garnish
NOTE:
9x V-clips, 1x guide tab
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- Move LH front seat to original position
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- Raise both LH side windows
 Courtesy of TESLA, INC.
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- Close LH front door