30/05/2024 08:25:07

Liftgate Assembly (Remove and Replace)

FRT No: 10107002

  • 2023-11-16: Added note to the beginning of this procedure for vehicles with manual liftgates.
  • 2023-10-25: All replacement liftgates must be reworked so that they can be installed on classic Model S. This procedure has been updated to include rework instructions.
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Note
Vehicles with manual liftgates: procure and install the liftgate pinch sensors as instructed in this procedure. Tape and secure the pinch sensor harnesses so as to prevent potential NVH.

Removal

  1. Open all four doors
  2. Lower all four windows
  3. Move LH front seat forward
  4. Move RH front seat forward
  5. Fold 60 and 40 seat into down position
  6. Remove rear license plate
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    Note
    4x screws, phillips head
  7. Open liftgate
  8. Remove parcel shelf
  9. Remove trunk load floor
  10. Remove upper liftgate trim
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    Note
    4x clips, Replace any damaged clips
  11. Remove liftgate LH side trim panel
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    Note
    3x clips, Replace any damaged clips
  12. Remove liftgate RH side trim panel
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    Note
    3x clips, Replace any damaged clips
  13. Remove pull cups from lower liftgate trim assembly
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    Note
    1x connector, If equipped with power liftgate
  14. Remove screws securing lower liftgate trim to body
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    Note
    2x screws, T20, 3 Nm
  15. Remove lower liftgate trim
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    Note
    10x clips, 4x connectors, Number of connections may vary, Take care not to damage connectors when releasing trim
  16. Disconnect CHMSL
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    Note
    1x connector
  17. Remove LH antenna amplifier
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    Note
    1x screw, T25, 1.2 Nm, 3x connectors
  18. Remove LH RF filter
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    Note
    1x bolt, T30, 2 Nm, 1x connector, Discard after removal
  19. Remove RH antenna amplifier
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    Note
    1x screw, T25, 1.2 Nm, 2x connector
  20. Remove RH RF filter
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    Note
    1x bolt, T30, 2 Nm, 2x connector, Discard after removal, Remove component from wiring harness
  21. Disconnect RH tail lamp
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    Note
    1x connector
  22. Disconnect LH tail lamp
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    Note
    1x connector
  23. Remove bolt securing liftgate grounding terminals
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    Note
    1x bolt, 10mm, 9 Nm, 2x ground terminals
  24. Remove clips securing harnesses to liftgate assembly
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    Note
    13x fir tree clips, 1x edge clip
  25. Tuck the exposed wire harness into the rear liftgate
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    Note
    Caution not to damaged harness when closing the liftgate in the next step
  26. Close liftgate
  27. Remove liftgate applique
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    Note
    5x clips Recommend using the badge removal wire to release adhesive on the tail lamps, Note the center of the applique is secured by clips, Take care not to damage applique or body
  28. Open liftgate
  29. Remove LH reverse tail lamp from liftgate
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    Note
    4x nuts, 8mm, 4 Nm, 2x rubber covers, Remove rubber covers
  30. Remove RH reverse tail lamp from liftgate
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    Note
    4x nuts, 8mm, 4 Nm, 2x rubber covers, Remove rubber covers
  31. Disconnect LH liftgate pinch strip sensor
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    Note
    1x connector
  32. Remove LH rear liftgate pinch strip assembly from the liftgate
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    Note
    6x push clip
  33. Remove LH pinch strip grommet and remove the pinch strip from the liftgate
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    Note
    1x grommet
  34. Disconnect RH liftgate pinch strip sensor
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    Note
    1x connector
  35. Remove RH rear liftgate pinch strip assembly from the liftgate
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    Note
    6x push clip
  36. Remove RH pinch strip grommet and remove the pinch strip from the liftgate
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    Note
    1x grommet
  37. Remove bolts and screws securing rear view camera to bracket and bracket to liftgate
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    Note
    3x screws, T20, 2.4 Nm, 2x bolt, T25, 2.4 Nm, Discard rear view camera bolts after removal
  38. Install protective tape on rear view camera
  39. Remove rear view camera from liftgate
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    Note
    1x connector, 1x grommet, Take care not to let the rear view camera drop on the ground when releasing it from the liftgate
  40. Remove LH and RH license plate lamps
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    Note
    2x connector, 2x lamps, Depress the locking tab on the license plate lamp to release
  41. Close liftgate
  42. Clean rear glass and secure double suction cup handles onto both side of liftgate glass
  43. Apply tape to body surrounding liftgate glass for protection
  44. Cut length of square wire to use with T-handles
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    Note
    Make sure there's adequate wire
  45. Attach one side of wire to a T-handle
  46. Secure wire to starter tool and push tool through urethane at upper left side
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    Note
    Push starter wire tool in between liftgate glass and CHMSL
  47. Remove wire from starter tool and secure square wire into one T-handle
  48. Remove wire starter tool from vehicle
  49. Cut out and remove rear liftgate glass
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    Note
    Recommend assistance, if wire is getting caught on center high mounted stop lamp, equalizer can be used to separate CHMSL from liftgate glass
  50. Remove protective tape from body
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    Note
    Inspect for any nicks that may need touch up
  51. Remove urethane from the liftgate glass and body
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    Note
    A recommended method for this step is to grip a razor blade with a pair of pliers. Touch the blade to the body and gently push downwards
  52. Open liftgate
  53. Remove LH and RH liftgate drain plug
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    Note
    2x drain plug
  54. Remove bolts securing LH and RH liftgate wedge bumpers to liftgate
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    Note
    2x bolt, T30, 12 Nm, 2x caps
  55. Remove LH and RH lower bumps from liftgate
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    Note
    2x bump stop
  56. Disconnect liftgate latch
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    Note
    1x connector
  57. Remove liftgate latch emergency release cable from rear liftgate
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    Note
    1x edge clip
  58. Remove emergency liftgate release cable tether from end of release cable
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    Note
    Peel of the butyl and remove cable
  59. Remove liftgate latch assembly from liftgate
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    Note
    2x bolts, T30, 10 Nm
  60. Remove bolts securing liftgate release button to liftgate
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    Note
    2x bolts, 10mm / T30, 3 Nm
  61. Remove liftgate release button from liftgate
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    Note
    1x connector
  62. Release RH liftgate harness grommet from liftgate
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    Note
    1x grommet
  63. Place a fender cover on vehicle RH side
  64. Pull wire harness through RH top liftgate grommet hole
  65. Release LH liftgate harness grommet from body
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    Note
    1x grommet
  66. Place a fender cover on vehicle LH side
  67. Route LH liftgate harness through grommet hole
  68. Disconnect GPS antenna from LH liftgate harness
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    Note
    Remove tape as needed
  69. Remove GPS antenna from liftgate
  70. Support liftgate
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    Note
    Need assistance
  71. Disconnect LH and RH liftgate struts from liftgate
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    Note
    2x strut clip
  72. Remove LH liftgate strut ball stud from liftgate
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    Note
    1x patched ball stud, 13mm, 22 Nm, Discard after removal
  73. Remove RH liftgate strut ball stud from liftgate
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    Note
    1x patched ball stud, 13mm, 22 Nm, Discard after removal
  74. Remove RH rear C-pillar trim
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    Note
    1x screw, T25, 3 Nm, 4x clips
  75. Remove RH upper C-pillar trim
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    Note
    4x clips
  76. Remove bolt securing headliner and support strap at RH C-pillar
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    Note
    1x bolt, 8mm, 10 Nm
  77. Remove LH rear C-pillar trim
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    Note
    1x screw, T25, 3 Nm, 4x clips
  78. Remove LH C-pillar upper trim
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    Note
    4x clips
  79. Remove bolt securing headliner and support strap at LH C-pillar
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    Note
    1x bolt, 8mm, 10 Nm
  80. Release rear of headliner and lower
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    Note
    5x clips, 3x velcro strips
  81. Close liftgate
  82. Remove nuts securing liftgate hinge to body
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    Note
    4x nuts, 10mm, 16 Nm, Remove from inside of the vehicle, Move butyl patch aside to expose nuts securing liftgate hinge to body
  83. Remove liftgate from vehicle
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    Note
    Recommend assistance

Install

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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. Prepare liftgate for installation
  2. Install RH liftgate strut ball stud onto liftgate
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    Note
    1x patched ball stud, 13mm, 22 Nm, Install new patched ball stud
  3. Install LH liftgate strut ball stud onto liftgate
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    Note
    1x patched ball stud, 13mm, 22 Nm, Install new patched ball stud
  4. Install liftgate onto vehicle
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    Note
    4x nuts, 10mm, 16 Nm, Recommend assistance, Do not fully tighten the liftgate in this step
  5. Connect RH liftgate strut onto liftgate
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    Note
    1x strut clip
  6. Connect LH liftgate strut onto liftgate
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    Note
    1x strut clip
  7. Install license plate frame screw grommets onto liftgate
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    Note
    4x screw grommets
  8. Install applique bracket screw grommets onto liftgate
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    Note
    3x screw grommets
  9. Use tape and wrap up right side wire harness to protect connectors during installation
  10. Use tape and wrap up left side wire harness to protect connectors during installation
  11. Route RH liftgate harness through grommet hole
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    Note
    Use zip ties and tape as needed
  12. Secure RH liftgate harness grommet onto liftgate
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    Note
    1x grommet, Apply P-80 onto grommet for easier fit
  13. Route LH liftgate harness through grommet hole
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    Note
    Use zip ties as needed
  14. Route GPS antenna connector through LH top liftgate grommet hole
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    Note
    Route GPS antenna from outside, Remove red double sided tape cover and attach GPS antenna onto liftgate
  15. Connect GPS antenna onto LH liftgate harness
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    Note
    1x connector, apply tape as needed
  16. Secure LH liftgate harness grommet onto body
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    Note
    1x grommet, Apply P-80 onto grommet for easier fit, Make sure its fully installed
  17. Connect RH liftgate pinch strip sensor
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    Note
    1x connector, Route harness trough RH liftgate grommet opening
  18. Install RH pinch strip grommet onto liftgate
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    Note
    1x grommet, Apply P-80 onto grommet for easier fit
  19. Install RH rear liftgate pinch strip assembly onto liftgate
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    Note
    6x push clip
  20. Connect LH liftgate pinch strip sensor
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    Note
    1x connector, Route harness trough LH liftgate grommet opening
  21. Install LH pinch strip grommet onto liftgate
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    Note
    1x grommet, Apply P-80 onto grommet for easier fit
  22. Install LH rear liftgate pinch strip assembly onto liftgate
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    Note
    6x push clip
  23. Remove protective tape from RH side liftgate wire harness
  24. Remove protective tape from LH side liftgate wire harness
  25. Install clips securing harnesses to liftgate assembly
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    Note
    13x fir tree clips, 1x edge clip
  26. Remove painted ground bolts from liftgate
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    Note
    7x bolts, 10mm, 9 Nm, Preparing for later mounting
  27. Install RH reverse tail lamp onto liftgate
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    Note
    4x nuts, 8mm, 4 Nm, 2x rubber covers
  28. Install LH reverse tail lamp onto liftgate
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    Note
    4x nuts, 8mm, 4 Nm, 2x rubber covers
  29. Connect RH tail lamp
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    Note
    1x connector
  30. Connect LH tail lamp
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    Note
    1x connector
  31. Install RH lower bump onto liftgate
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    Note
    1x bump stop
  32. Install LH lower bump onto liftgate
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    Note
    1x bump stop
  33. Install liftgate grounding terminals
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    Note
    2x bolt, 10mm, 9 Nm, 2x ground terminals
  34. Install liftgate latch assembly onto liftgate
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    Note
    2x bolts, T30, 10 Nm
  35. Connect liftgate latch
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    Note
    1x connector
  36. Install liftgate latch emergency release cable onto rear liftgate
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    Note
    1x edge clip
  37. Install emergency liftgate release cable tether onto end of release cable
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    Note
    Use new piece of butyl tape if old doesn't hold
  38. Install rear liftgate emergency cable into place
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    Note
    1x edge clip, To avoid NVH issues make sure the cable is firmly secured
  39. Install piece of dual lock onto rear liftgate
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    Note
    Install in area near emergency release cable, Used as an anchor for the emergency release cable
  40. Install liftgate release button onto liftgate
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    Note
    1x connector
  41. Install bolts securing liftgate release button to liftgate
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    Note
    2x bolts, 10mm, 3 Nm
  42. Install RH license plate lamp onto liftgate
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    Note
    Make sure you hear the locking tab snap into place holding the plate light in place
  43. Connect RH license plate lamp
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    Note
    1x connector
  44. Install LH license plate lamp onto liftgate
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    Note
    Make sure you hear the locking tab snap into place holding the plate light in place
  45. Connect LH license plate lamp
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    Note
    1x connector
  46. Install LH and RH liftgate drain plug
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    Note
    2x drain plug
  47. Install rear view camera harness onto liftgate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x edge clip
  48. Install rear view camera into liftgate
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    Note
    1x grommet, Apply P-80 onto grommet for easier fit
  49. Connect rear view camera
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    Note
    1x connector 1x clip
  50. Remove protective tape from rear view camera
  51. Install bolts securing rear view camera onto bracket
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    Note
    2x bolt, T25, 2.4 Nm, Install new patched bolts, Thread the rear facing camera into the rear liftgate applique bracket
  52. Install screws securing bracket onto liftgate
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    Note
    3x screws, T20, 2.4 Nm
  53. Install RH liftgate wedge bumper onto liftgate
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    Note
    1x bolt, T30, 12 Nm, 1x cap
  54. Install LH liftgate wedge bumper onto liftgate
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    Note
    1x bolt, T30, 12 Nm, 1x cap
  55. Inspect that all harness clips are in place
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    Note
    Make sure that harness will not get damaged if the rear liftgate is closed
  56. Close liftgate
  57. Check gap and flush from liftgate to body
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    Note
    Reference gap and flush specification guide on service manual, Adjust if needed, https://service.teslamotors.com/protected-doc/ModelS/TheoryOp/InspectionStandards/index_frames.html
  58. Torque nuts securing liftgate hinge to body
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    Note
    4x nuts, 10mm, 16 Nm, Torque from inside of the vehicle
  59. Use an IPA wipe to clean CHMSL mounting location
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    Note
    Allow IPA to dry for at least one minute
  60. Use an IPA wipe to clean urethane path on liftgate glass
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    Note
    Allow IPA to dry for at least one minute
  61. Use an IPA wipe to clean urethane path on body
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    Note
    Allow IPA to dry for at least one minute
  62. Print out CHMSL template and cut it out
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    Note
    http://toolbox.teslamotors.com/media/attachments/shared/7741afaa-ded3-4e7b-b003-209c5678960a.pdf
  63. Place CHMSL templates on liftgate glass in upper corner of glass and secure template with tape
  64. Reconnect the CHMSL to the harness in the center of the liftgate
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    Note
    1x connector
  65. Test if CHMSL is working correctly
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    Note
    Have an assistant depress the brake pedal, Ensure that the CHMSL lights up properly, If any of the LEDs have been damaged, Replace the CHMSL, If wire has been damaged repair wire following bulletin, https://service.teslamotors.com/protected-doc/ServiceBulletins/Internal/SI/SI-17-17-002_Electrical_Harness_Repair_R6.pdf
  66. Disconnect CHMSL assembly
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    Note
    1x connector
  67. Remove old double sided tape from CHMSL
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    Note
    Use glue remover
  68. Use an IPA wipe to clean double sided tape path on CHMSL assembly
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    Note
    Allow IPA to dry for at least one minute
  69. Apply new double sided tape to CHMSL
  70. Remove red tape covers from CHMSL
  71. Secure CHMSL to liftgate glass
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    Note
    Place in upper corners of template, Apply pressure to adhere 3M tape to liftgate glass
  72. Remove CHMSL templates from liftgate glass
  73. Secure CHMSL harness to liftgate glass
  74. Secure double suction cup to outside of new rear liftgate glass
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    Note
    2x double suction cup handles, 1 on each side of glass
  75. Flip over rear liftgate glass and install it onto vehicle
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    Note
    2x double suction cup handles, 1 on each side of glass, Recommend assistance
  76. Check gap and flush of liftgate glass
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    Note
    Make notes of any needed adjustments
  77. Remove rear liftgate glass
    Informational PurposesAn informational icon, calling your attention
    Note
    2x double suction cup handles, 1 on each side of glass
  78. Apply urethane primer to liftgate glass along urethane path
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    Note
    Allow primer to dry for 2 minutes before applying urethane
  79. Apply urethane primer to liftgate body along urethane path
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    Note
    Allow primer to dry for 2 minutes before applying urethane
  80. Prepare caulking gun and urethane
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    Note
    Opening must be 8mm wide and 14mm tall
  81. Apply urethane to liftgate body following primer patch
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    Note
    Fill any gaps in urethane to ensure consistent bead
  82. Flip over rear liftgate glass and install it onto vehicle
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    Note
    2x double suction cup handles, 1 on each side of glass, Recommend assistance
  83. Check gap and flush of liftgate glass
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    Note
    Use tape to hold glass in place, allow glass 10 minutes of dry time before opening liftgate
  84. Remove suction cups from liftgate glass
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    Note
    2x double suction cup handles
  85. Clean adhesive from applique bracket and liftgate tail lamp assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean off residue, Recommend using your thumb to help roll off the adhesive, Allow 1 minute for IPA to dry
  86. Install applique tape onto applique bracket and applique
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    Note
    Be careful not to cover the rear view camera
  87. Remove adhesive backing from applique bracket and liftgate applique
  88. Install the liftgate applique
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    Note
    5x clips, Align applique using pin, Start by securing center clips and work your way out towards the tail lamps, Do not allow the ends to adhere before securing the center
  89. Install "Model S" badge onto liftgate
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    Note
    Use an IPA wipe to clean area, Allow IPA to dry for at least one minute
  90. Install Tesla "T" badge onto liftgate
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an IPA wipe to clean area, Allow IPA to dry for at least one minute
  91. Install "Battery Size" badge onto liftgate
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    Note
    Use an IPA wipe to clean area, Allow IPA to dry for at least one minute
  92. Open liftgate
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow for dry time
  93. Untuck the protected rear liftgate wire harness
  94. Install LH and RH lower liftgate trim screw grommets
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    Note
    2x screw grommet
  95. Install RH RF filter
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    Note
    1x bolt, T30, 2 Nm, 2x connectors, Install new patch bolt
  96. Rework LH and RH antenna amplifiers
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    Note
    2x clips, 2x tabs, Remove clip from tab then using side cutter pliers cut off tab, File off excess material to create flush surface, Apply double sided tape onto antenna amplifiers, Careful damage antenna amplifiers when reworking
  97. Install RH antenna amplifier
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T25 / 10mm, 1.2 Nm, 2x connector
  98. Connect CHMSL
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  99. Install LH RF filter
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T30, 2 Nm, 1x connector, Install new patched bolt
  100. Install LH antenna amplifier
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T25 / 10mm, 1.2 Nm, 2x connectors
  101. Install lower liftgate trim
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    Note
    10x clips, 4x connectors, Number of connections may vary, Replace any damaged clips
  102. Install RH side liftgate trim
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    Note
    3x clips, Replace any damaged clips
  103. Install LH side liftgate trim
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    Note
    3x clips, Replace any damaged clips
  104. Install upper liftgate trim
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    Note
    4x clips, Replace any damaged clips
  105. Install parcel shelf
  106. Install trunk load floor
  107. Install rear portion of headliner into position and clip into place
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    Note
    5x clips, 3x velcro strips, Replace any damaged or missing clips
  108. Install bolt securing headliner and support strap at LH C-pillar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 8mm, 10 Nm
  109. Install LH C-pillar upper trim
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    Note
    4x clips
  110. Install LH rear C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T25, 3 Nm, 4x clips
  111. Install bolt securing headliner and support strap at RH C-pillar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 8mm, 10 Nm
  112. Install RH upper C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  113. Install RH rear C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T25, 3 Nm, 4x clips
  114. Install liftgate pull cups into rear liftgate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, If equipped with power liftgate
  115. Close liftgate
  116. Fold 60 and 40 seat into vertical position
  117. Close all doors
  118. Return RH front seat to original position
  119. Return LH front seat to original position
    Informational PurposesAn informational icon, calling your attention
    Note
    Utilize driver profile settings to return customer seat settings if saved
  120. Raise all four windows
  121. Close both front doors