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How to repair your Tesla Model S Door handle (DIY Kit)

Published

5 years ago

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The sudden failure of Tesla Model S self-presenting door handles as a result of component failure is a common and often aggravating experience for many early owners.

The design of the earlier Model S door handle was comprised of cheaper, cast components that often led to breakage, which Tesla finally addressed in the 3rd Gen of Model S door handles.

Under warranty, the answer is simple; call the service center, and schedule an appointment for a replacement, but for many early Model S owners, their warranty has been long gone, and thus stuck with an expensive repair bill that ran upwards of $1000.00 per self-presenting door handle. It also requires a special calibration that only the service center can perform.

The owners of the Electrified Garage have addressed this common issue with a comprehensive DIY Model S Door Handle Rebuild Kit that any handy person can tackle.

The kit includes a stronger machined stainless steel gear, a new e-clip for retaining the pivot gear on the shaft, Original Equipment Panasonic replacement micro-switches, push nuts to hold the vapor barrier securely, and new door panel clips.

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Here’s a basic guideline on how to repair your Model S door handle.

To remove the door handle assembly

  1. With the door opened, pull the hatch into a position as if you were opening the door.
  2. Pop off the trim piece with a flat tool, like a flathead screwdriver. Do not apply excessive force.
  3. Use a Torx T30 bit to remove the two screws behind the door hatch.
  4. Use the 9mm socket wrench to remove the single bolt that lies under the door handle.
  5. Use your hands to pop the speaker grille off from the bottom portion of the door.
  6. Then grab the underside above the speaker and the door handle and pull the door covering off firmly.
  7. Remove any wiring that connects the door covering to the door itself. This includes lights, speaker system wires, and door sensor connectors.
  8. Use a Torx T20 bit to remove the door cover panel. There will be five screws to remove.
  9. Use a flathead to push the rubber gasket through the hole on the panel that was most recently removed.
  10. Use a flathead to push the switch on the side of the door. This will trick the window into thinking the door is closed, which will push the window glass upward. It will give you easier access to screws at the top of the door frame.
  11. Use a trim removal device or flat tool to remove the small white piece from the door panel. This secures the door handle harness into place.
  12. Unplug the door handle harness.
  13. Remove the two black plastic door covers from the door panel that are shown below. This is done by simply pressing from the back of the pieces with your hand.
  14. Use a 10mm socket wrench to remove the two bolts that are in each of these two holes and another that lies within the open space in the center of the door.
  15. Push the door handle on the exterior of the door back into the door assembly. Use your right hand to stabilize the door and your left hand to push the door handle in.
  16. Reconnect the blue window power wire into the appropriate connection point. This is located at the bottom of the door. Once this is completed, roll the window down and disconnect the connection once again.
  17. Grab the top chrome-colored trim piece located at the top of the outside of the door. Gently remove this piece by slightly pulling and working your way down the piece. Do this gradually and try not to remove it in one pull. It could damage the trim or the door itself.
  18. Remove the bolt located under the chrome trim piece. It is easiest to do this with a regular wrench and slowly loosen. You can wrap the wrench in electrical tape to prevent possible scratching of the window glass.
  19. Reconnect the blue window power connector once again and roll the window all the way up. Once the window is rolled up, disconnect the connector wire once again.
  20. The door assembly can then be pulled out. Pull in a firm, controlled fashion.

To repair the door assembly:

  1. Remove the vapor cover from the assembly. This is usually connected with zip ties. Be careful to not cut any wires while removing.
  2. Remove the five centrally located bolts with the correctly-sized Torx bits.
  3. Remove the motor, which is the small cylindrical black piece held in by these bolts.
  4. Remove the two screws that maintain the position of the door handle.
  5. Remove the pin that is housed on the rear side of the assembly. This can be lubricated with WD-40 and pushed out with a pair of needlenose pliers.
  6. Install the new gear into the door assembly by pressing down on the door handle.
  7. Slide the pin back through and make sure the center notch on the pin is aligned with the middle slot. Install a new metal clip from the kit in the center notch.
  8. Reinstall the screws that were removed in Step 4.
  9. Resecure the main power wire for the door handle to the bottom of the assembly with zip ties.
  10. Reinstall the motor from Step 3 and resecure it with the appropriate screws.
  11. Resecure all wires with zip ties and reapply the vapor cover.

Tesla Model S Door Handle DIY Repair Kit

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Joey has been a journalist covering electric mobility at TESLARATI since August 2019. In his spare time, Joey is playing golf, watching MMA, or cheering on any of his favorite sports teams, including the Baltimore Ravens and Orioles, Miami Heat, Washington Capitals, and Penn State Nittany Lions. You can get in touch with joey at joey@teslarati.com. He is also on X @KlenderJoey. If you're looking for great Tesla accessories, check out shop.teslarati.com

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Lifestyle

Tesla brings perhaps the coolest interior feature to cars in latest update

Tesla adds on to the “fun” aspect of its vehicles.

Published

2 weeks ago

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July 30, 2025

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Credit: Tesla

Tesla has brought perhaps the coolest interior feature to its cars in a new update that is rolling out to vehicles now.

The feature will require a newer vehicle that has interior ambient lighting, which is present on the new Model S, Model X, Model 3 “Highland,” and Model Y “Juniper.” The Cybertruck also has ambient lighting strips throughout.

Tesla Model Y’s ambient lighting design changes revealed in leaked video

With the Version 2025.26+ Software Update, Tesla is rolling out a new “Sync Accent Lights w/ Music” feature, which is available on the Tesla Toybox:

To enable the feature, you’ll access the Toybox, choose “Light Sync,” and then choose “Sync Accent Lights w/ Music.”

Although it does not improve the performance of the vehicle, it is yet another example of Tesla making one of the coolest cars out there. This is truly a cool add-on that can be used to impress your friends and family.

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Elon Musk

xAI, Musk Foundation helps schools near Memphis supercomputer site

Reports of xAI and the Musk Foundation’s work were recently posted by local news media.

Published

2 weeks ago

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July 26, 2025

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xAI-supercomputer-memphis-environment-pushback
(Credit: xAI)

Elon Musk’s artificial intelligence startup xAI and the Musk Foundation have been supporting Memphis-Shelby County Schools with HVAC repairs and facility upgrades, while also funding youth programs for students in the area. 

Reports of xAI and the Musk Foundation’s work were recently posted by local news media.

xAI’s school visits lead to facility repairs

Representatives from xAI visited John P. Freeman Optional School, Fairley High School, and Westwood High School, all of which are located near its Colossus supercomputer site, to assess HVAC systems, plumbing, gym facilities, and athletic fields. The visits resulted in a list of priority repairs, some of which were completed in April and May.

In addition to the repairs, xAI also shared a number of initiatives that are planned for students in the area, as stated in a Commercial Appeal report.

“xAI is working on providing STEM workshops for local students, donating equipment to technical training programs, and supporting job fairs to boost employment opportunities. These initiatives reflect xAl’s commitment to fostering education and economic growth in Memphis,” xAI noted in a statement.

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Musk Foundation donation

Apart from xAI, the Musk Foundation also donated $350,000 to the Boys & Girls Clubs of Greater Memphis, enabling the reopening of two club sites located at Booker T. Washington High School and Westwood High School. Both locations had closed earlier this year due to lapses in funding. As per xAI, the Musk Foundation’s donation allows clubs to reopen for almost 1,000 students. 

The donation will fund staffing, supplies, and transportation, among others. “Kids are the future of humanity,” Elon Musk said in a statement, adding that students need “every chance to shoot for the stars.”

“We’re honored to support the Boys & Girls Clubs of Greater Memphis in reopening these sites, giving kids in underserved communities the tools to build brighter futures,” Musk said.

The gift was praised by local officials, including Boys & Girls Clubs board chair Michael Garriga, who stated that the “commitment will ensure the youth of our community have the opportunities they need to develop their skills and talents to become successful students and future citizens.”

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Lifestyle

EV fans urge Tesla to acquire Unplugged Performance for edge in fleet and security industry

Unplugged Performance has built a name for itself by producing performance upgrades for Tesla vehicles.

Published

4 weeks ago

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July 12, 2025

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Credit: Unplugged Performance

A growing number of Tesla enthusiasts and longtime community voices are calling on the electric vehicle maker to acquire Unplugged Performance, a California-based aftermarket company best known for tuning Tesla vehicles and developing specialized government fleet solutions under its UP.FIT division.

The idea was once considered a niche proposal among EV fans, but it is now gaining serious attention not just as a performance play but as a strategic move to deepen Tesla’s roots in the fleet and security industry. 

A strategic fit

Unplugged Performance has built a name for itself by producing performance upgrades for Tesla vehicles, from track-optimized components to visual and aerodynamic upgrades. But in recent years, its UP.FIT division has pivoted toward a more functional future by outfitting Tesla vehicles like Model Ys for police, military, and government use.

That work has sparked growing calls for closer collaboration with Tesla, especially as the EV maker increasingly leans into autonomy, AI, and fleet services as core components of its next chapter.

“I posted this four years ago, but I think it’s more true now than ever,” wrote Whole Mars Catalog, a well-known Tesla investor and FSD Beta tester, on X. “Tesla should buy Unplugged. But not just as a Performance division. What they are doing with UP.FIT unlocks large government and commercial fleet purchases that can improve utilization.”

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Tesla fans such as shareholder Sawyer Merritt echoed the sentiment, calling Unplugged a “great fit within Tesla.” adding, “They are literally located directly next to Tesla’s design studio in Hawthorne.”

Enabling the next wave

Supporters of the idea noted that integrating Unplugged into Tesla’s corporate structure could help accelerate the adoption of autonomous technologies in government sectors. With UP.FIT patrol cars already in use across some U.S. police departments, Tesla fans envisioned a future where self-driving Teslas could potentially revolutionize law enforcement, search-and-rescue, and public service logistics.

“Just imagine how autonomous patrol cars could transform policing and bring us into a safer future,” the veteran FSD tester wrote.

The benefits could also extend to Tesla’s existing consumer base. “They also have some incredible products in the works that I think will appeal to many ordinary Tesla drivers — not just those looking for performance or mods. Stuff that’s so good it should have come straight from the design studio next door,” Whole Mars Catalog noted.

Unplugged Performance, founded in 2013, shares not just a product vision with Tesla, but also geography. Its Hawthorne headquarters sits directly adjacent to Tesla’s design studio, and the two companies have maintained a close working relationship over the years. The aftermarket firm has long positioned itself as a “mission-aligned” partner to Tesla.

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In response to the recent calls for acquisition, Unplugged Performance acknowledged the support from the community. “Our very existence is to support the Tesla mission with @UpfitTesla and @UnpluggedTesla,” Unplugged CEO Ben Schaffer posted on X. “We love working with Tesla and are grateful for the community’s support since 2013!”

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