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Body Repair Tech Note: Replacing Model S Doors

specified in the Parts Manual. BR-17-11-003 R3 Page 5 of 5 Right-Hand Rear Doors To install a new right-hand rear door (Tesla part number 6006566-E0-G) on a vehicle that has the rear doors that originally came on vehicl…

Body Repair Tech Note: Replacing Model S Doors - I-CAR ...

NOTE: Refer to Service Manual procedure 11451006 for door handle installation instructions. Page 3. BR-17-11-003 R3. Page 3 of 5.

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BR-17-11-003 R3 August 21, 2018

Tesla, Inc. Body Repair Tech Notes

Body Repair Tech Note: Replacing Model S Doors
Body Repair Tech Notes provide information about Tesla-approved methods and practices for body repair. These instructions assume knowledge of motor vehicle and high voltage electrical component repairs, and should only be executed by trained professionals. Tesla assumes no liability for injury or property damage due to a failure to properly follow these instructions or for repairs attempted by unqualified individuals.
This Body Repair Tech Note supersedes BR-17-11-003 R2, dated 25-Jan-18. Each content change is marked by a vertical line in the left margin. Discard the previous version and replace it with this one.
The front and rear doors on Model S vehicles built after October 26, 2016 have different mounting points for the door handles than those on vehicles built through October 26, 2016. The doors that originally came on vehicles built through October 26, 2016 are no longer being produced and cannot be ordered.
When replacing a door on a vehicle built through October 26, 2016 that has the original doors, order a new handle and associated parts to fit the mounting points on the replacement door. Refer to the "Parts Required for Front Doors" and "Parts Required for Rear Doors" sections of this document.
NOTE: After installing a new door handle, connect a laptop with Toolbox installed and perform the "3.0 Door Handle Calibration" procedure.
NOTE: If the door on a vehicle built through October 26, 2016 has already been replaced with a door for vehicles built after October 26, 2016, a new handle and associated parts will not be needed. To identify the version of door on the vehicle, refer to the "Identifying the Door Version" section of this document.
Identifying the Door Version
Use the images below to identify the version of door in the vehicle being repaired.
Front Doors
Front doors that originally came on vehicles built through October 26, 2016 (Figure 1) differ from the front doors that originally came on vehicles built after October 26, 2016 (Figure 2) both by differences in the opening for the door handle and the changes in the door handle mounting points (circled in red).

Figure 1 (Left-hand front door for vehicles built through October 26, 2016, trim removed)

Figure 2 (Left-hand front door for vehicles built after October 26, 2016, trim removed)

BR-17-11-003 R3

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Rear Doors
Rear doors that originally came on vehicles built through October 26, 2016 (Figure 3) differ from the rear doors that originally came on vehicles built after October 26, 2016 (Figure 4) both by differences in the opening for the door handle and the changes in the door handle mounting points (circled in red).

Figure 3 (Left-hand rear door for vehicles built through October 26, 2016, trim removed)

Figure 4 (Left-hand rear door for vehicles built after October 26, 2016, trim removed)

Parts Required for Front Doors
When replacing a door on a vehicle built through October 26, 2016 that has the original doors, use the sections below to determine what additional parts need to be ordered.
NOTE: Refer to Service Manual procedure 11451006 for door handle installation instructions.

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Left-Hand Front Doors

To install a new left-hand front door (Tesla part number 6006662-E0-G) on a vehicle that has the front doors that originally came on vehicles built through October 26, 2016, order the parts listed below.

Part Number Quantity

Description

Notes

1100299-S0-A

1

ASSY � EXT HANDLE, LH, GEN 3, NO GRIP, SVC

1069106-00-B

1

ASY,PIGTAIL,MDLS,DOOR HANDLE,FRONT

1063215-00-B

1

HARD COVER, EXT. DOOR HANDLE, LH

1069651-00-C

1

ASSEMBLY, DOOR HANDLE 3.0 CTLR

1037847-00-D

1

ASY PLATE, FR DOOR, LH

1109173-00-A

1

LED ASY, DOOR HANDLE 3.0 OUTER LH

1015888-00-C

6

BLT,BTN,TRX,M5x16[10.9]-BK-X-SP-05

1069401-00-A

5

SCREW,FC,50x15,STL,ZNNI,DELTAPT

1009289-00-B

1

SCREW,PF,50x12, DELTA PT

1016456-00-B

4

WSHR,6.0x18x1.6mm, EPOXY

1052476-00-A

2

SPACER, GRIP, EXT DIE CAST DOOR HANDLE

1052477-00-A

1

SPACER, GRIP, EXT DIE CAST DOOR HANDLE

Order only if using a metal grip from the original handle.
Order only if using a metal grip from the original handle.

NOTE: These part numbers were current at the time of publication. Use the revisions listed or later, unless otherwise specified in the Parts Manual.

Right-Hand Front Doors
To install a new right-hand front door (Tesla part number 6006622-E0-G) on a vehicle that has the front doors that originally came on vehicles built through October 26, 2016, order the parts listed below.

Part Number Quantity

Description

Notes

1100300-S0-A

1

ASSY � EXT HANDLE, RH, GEN 3, NO GRIP, SVC

1069106-00-B

1

ASY,PIGTAIL,MDLS,DOOR HANDLE,FRONT

1064744-00-B

1

HARD COVER, EXT. DOOR HANDLE, RH

1069651-00-C

1

ASSEMBLY, DOOR HANDLE 3.0 CTLR

1037846-00-D

1

ASY PLATE, FR DOOR, RH

1109174-00-A

1

LED ASY, DOOR HANDLE 3.0 OUTER RH

1015888-00-C

6

BLT,BTN,TRX,M5x16[10.9]-BK-X-SP-05

1069401-00-A

5

SCREW,FC,50x15,STL,ZNNI,DELTAPT

1009289-00-B

1

SCREW,PF,50x12, DELTA PT

1016456-00-B

4

WSHR,6.0x18x1.6mm, EPOXY

1052476-00-A

2

SPACER, GRIP, EXT DIE CAST DOOR HANDLE

1052477-00-A

1

SPACER, GRIP, EXT DIE CAST DOOR HANDLE

Order only if using a metal grip from the original handle.
Order only if using a metal grip from the original handle.

NOTE: These part numbers were current at the time of publication. Use the revisions listed or later, unless otherwise specified in the Parts Manual.

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Parts Required for Rear Doors
Left-Hand Rear Doors

To install a new left-hand rear door (Tesla part number 6006394-E0-G) on a vehicle that has the rear doors that originally came on vehicles built through October 26, 2016, order the parts listed below.
NOTE: Refer to Service Manual procedure 11452006 for door handle installation instructions.

Part Number Quantity

Description

Notes

1100299-S0-A

1

ASSY � EXT HANDLE, LH, GEN 3, NO GRIP, SVC

1069106-01-B

1

ASY,PIGTAIL,MDLS,DOOR HANDLE,REAR

1063215-00-B

1

HARD COVER, EXT. DOOR HANDLE, LH

1069651-00-C

1

ASSEMBLY, DOOR HANDLE 3.0 CTLR

1064363-00-A

1

PLATE, RR DOOR, LH

1109173-00-A

1

LED ASY, DOOR HANDLE 3.0 OUTER LH

1015888-00-C

6

BLT,BTN,TRX,M5x16[10.9]-BK-X-SP-05

1069401-00-A

5

SCREW,FC,50x15,STL,ZNNI,DELTAPT

1009289-00-B

1

SCREW,PF,50x12, ,DELTA PT

1016456-00-B

4

WSHR,6.0x18x1.6mm, EPOXY

1052476-00-A

2

SPACER, GRIP, EXT DIE CAST DOOR HANDLE

1052477-00-A

1

SPACER, GRIP, EXT DIE CAST DOOR HANDLE

Order only if using a metal grip from the original handle.
Order only if using a metal grip from the original handle.

NOTE: These part numbers were current at the time of publication. Use the revisions listed or later, unless otherwise specified in the Parts Manual.

BR-17-11-003 R3

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Right-Hand Rear Doors

To install a new right-hand rear door (Tesla part number 6006566-E0-G) on a vehicle that has the rear doors that originally came on vehicles built through October 26, 2016, order the parts listed below.

Part Number Quantity

Description

Notes

1100300-S0-A

1

ASSY � EXT HANDLE, RH, GEN 3, NO GRIP, SVC

1069106-01-B

1

ASY,PIGTAIL,MDLS,DOOR HANDLE,REAR

1064744-00-B

1

HARD COVER, EXT. DOOR HANDLE, RH

1069651-00-C

1

ASSEMBLY, DOOR HANDLE 3.0 CTLR

1067943-00-A

1

PLATE, RR DOOR, RH

1109174-00-A

1

LED ASY, DOOR HANDLE 3.0 OUTER RH

1015888-00-C

6

BLT,BTN,TRX,M5x16[10.9]-BK-X-SP-05

1069401-00-A

5

SCREW,FC,50x15,STL,ZNNI,DELTAPT

1009289-00-B

1

SCREW,PF,50x12, ,DELTA PT

1016456-00-B

4

WSHR,6.0x18x1.6mm, EPOXY

1052476-00-A

2

SPACER, GRIP, EXT DIE CAST DOOR HANDLE

1052477-00-A

1

SPACER, GRIP, EXT DIE CAST DOOR HANDLE

Order only if using a metal grip from the original handle.
Order only if using a metal grip from the original handle.

NOTE: These part numbers were current at the time of publication. Use the revisions listed or later, unless otherwise specified in the Parts Manual.

For feedback on the accuracy of this document, email BodyRepair@tesla.com.

BR-17-11-003 R3

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