Lifestyle
How to repair your Tesla Model S Door handle (DIY Kit)
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.
Here’s a basic guideline on how to repair your Model S door handle.
To remove the door handle assembly
- With the door opened, pull the hatch into a position as if you were opening the door.
- Pop off the trim piece with a flat tool, like a flathead screwdriver. Do not apply excessive force.
- Use a Torx T30 bit to remove the two screws behind the door hatch.

- Use the 9mm socket wrench to remove the single bolt that lies under the door handle.

- Use your hands to pop the speaker grille off from the bottom portion of the door.

- Then grab the underside above the speaker and the door handle and pull the door covering off firmly.

- Remove any wiring that connects the door covering to the door itself. This includes lights, speaker system wires, and door sensor connectors.

- Use a Torx T20 bit to remove the door cover panel. There will be five screws to remove.

- Use a flathead to push the rubber gasket through the hole on the panel that was most recently removed.

- 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.

- 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.

- Unplug the door handle harness.

- 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.

- 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.
- 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.

- 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.

- 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.
- 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.

- 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.

- The door assembly can then be pulled out. Pull in a firm, controlled fashion.
To repair the door assembly:
- Remove the vapor cover from the assembly. This is usually connected with zip ties. Be careful to not cut any wires while removing.

- Remove the five centrally located bolts with the correctly-sized Torx bits.

- Remove the motor, which is the small cylindrical black piece held in by these bolts.

- Remove the two screws that maintain the position of the door handle.
- 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.

- Install the new gear into the door assembly by pressing down on the door handle.

- 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.

- Reinstall the screws that were removed in Step 4.
- Resecure the main power wire for the door handle to the bottom of the assembly with zip ties.

- Reinstall the motor from Step 3 and resecure it with the appropriate screws.

- Resecure all wires with zip ties and reapply the vapor cover.
Elon Musk
The FCC just said ‘No’ to SpaceX for now
SpaceX is fighting the FCC for spectrum that could put satellites inside every smartphone.
SpaceX was dealt a new setback on April 23, 2006 by the Federal Communications Commission (FCC) after the U.S. government agency dismissed the company’s petition to access a Mobile Satellite Service spectrum that would allow direct-to-device (D2D) capabilities.
The FCC regulates communications by radio, television, wire, and cable, which also includes regulating D2D technology that lets your existing smartphone connect directly to a satellite orbiting Earth, the same way it would connect to a cell tower.
Elon Musk’s SpaceX has been building toward this through its Starlink Mobile service, formerly called Direct-to-Cell, in partnership with T-Mobile. The service officially launched on July 23, 2025, starting with messaging and expanding to broadband data in October of that year.
T-Mobile Starlink Pricing Announced – Early Adopters Get Exclusive Discount
It’s worth noting that SpaceX is not alone in this race. AT&T and Verizon have their own satellite texting deals with AST SpaceMobile, while Verizon separately offers free satellite texting through Skylo on newer phones.
The regulatory foundation for all of this dates to March 14, 2024, when the FCC adopted the world’s first framework for what it called Supplemental Coverage from Space, allowing satellite operators to lease spectrum from terrestrial carriers and fill gaps in their coverage. On November 26, 2024, the FCC granted SpaceX the first-ever authorization under that framework, approving its partnership with T-Mobile to provide service in specific frequency bands. SpaceX then went further, completing a roughly $17 billion acquisition of wireless spectrum from EchoStar, which gave it the ability to negotiate with global carriers more independently.
Starlink’s EchoStar spectrum deal could bring 5G coverage anywhere
This recent ruling by the FCC blocked SpaceX from going further, protecting incumbent spectrum holders like Globalstar and Iridium. But the market momentum is already in motion. As Teslarati reported, SpaceX is targeting peak speeds of 150 Mbps per user for its next generation Direct-to-Cell service, compared to roughly 4 Mbps today, which would bring satellite connectivity close to standard carrier performance.
With a reported IPO targeting a $1.75 trillion valuation on the horizon, each spectrum fight, carrier deal, and regulatory win or loss now carries weight beyond just connectivity. SpaceX is quietly becoming the infrastructure layer underneath the phones of millions of people, and the FCC’s next move will help determine how much further that reach extends.
FCC Satellite Rule Makings can be found here.
Elon Musk
Elon Musk talks Tesla Roadster’s future
Elon Musk confirmed the Roadster as Tesla’s last manually driven car, with a debut coming soon.
During Tesla’s Q1 2026 earnings call on April 22, Elon Musk made a brief but notable comment about the long-awaited next generation Roadster while describing Tesla’s future vehicle lineup. “Long term, the only manually driven car will be the new Tesla Roadster,” he said. “Speaking of which, we may be able to debut that in a month or so. It requires a lot of testing and validation before we can actually have a demo and not have something go wrong with the demo.”
That single statement is the entire Roadster update from yesterday’s call, and while it represents another timeline shift, it comes as no surprise with Tesla heads-down-at-work on the mass rollout of its Robotaxi service across US cities, and the industrial scale production of the humanoid Optimus.
The fact that Musk specifically framed the Roadster as the last manually driven Tesla is significant on its own. As the rest of the lineup moves toward full autonomy, the Roadster becomes something rare in the Tesla-sphere by keeping the driver in control. Driving enthusiasts who buy a $200,000 supercar are not doing so to be passengers. They want the physical connection to the road, the feel of acceleration under their own input, and the experience of controlling something with that level of performance. FSD, however capable it becomes, removes that entirely. The Roadster signals that Tesla understands this distinction and is building a car specifically for the people who consider driving itself the point.
Tesla isn’t joking about building Optimus at an industrial scale: Here we go
The specs for the Roadster Musk has teased over the years are genuinely unlike anything in production. The base model targets 0 to 60 mph in 1.9 seconds, a top speed above 250 mph, and up to 620 miles of range from a 200 kWh battery. The optional SpaceX package takes it further, rumored to add roughly ten cold gas thrusters operating at 10,000 psi, borrowed directly from Falcon 9 rocket technology. With thrusters, Musk has claimed 0 to 60 mph in as little as 1.1 seconds. In a 2021 Joe Rogan interview he went further, stating “I want it to hover. We got to figure out how to make it hover without killing people.” Tesla filed a patent for ground effect technology in August 2025, suggesting the hover concept has not been abandoned. The starting price remains $200,000, with the Founders Series requiring a $250,000 full deposit. Some reservation holders placed those deposits in 2017 and are approaching a full decade of waiting.
With production now targeted for 2027 or 2028 at the earliest, the Roadster remains Tesla’s most audacious promise and its longest-running delay. But if what Musk is testing lives up to even half of what he has described, the demo alone should be worth waiting for.
Elon Musk says the Tesla Roadster unveiling could be done “maybe in a month or so.”
He said it should be an extraordinary unveiling event. pic.twitter.com/6V9P7zmvEm
— TESLARATI (@Teslarati) April 22, 2026
Elon Musk
Tesla isn’t joking about building Optimus at an industrial scale: Here we go
Tesla’s Optimus factory in Texas targets 10 million robots yearly, with 5.2 million square feet under construction.
Tesla’s Q1 2026 Update Letter, released today, confirms that first generation Optimus production lines are now well underway at its Fremont, California factory, with a pilot line targeting one million robots per year to start. Of bigger note is a shared aerial image of a large piece of land adjacent to Gigafactory Texas, that Tesla has prominently labeled “Optimus factory site preparation.”
Permit documents show Tesla is seeking to add over 5.2 million square feet of new building space to the Giga Texas North Campus by the end of 2026, at an estimated construction investment of $5 billion to $10 billion. The longer term production target for that facility is 10 million Optimus units per year. Giga Texas already sits on 2,500 acres with over 10 million square feet of existing factory floor, and the North Campus expansion is being built to support multiple projects, including the dedicated Optimus factory, the Terafab chip fabrication facility (a joint Tesla/SpaceX/xAI venture), a Cybercab test track, road infrastructure, and supporting facilities.
Texas makes strategic sense beyond the existing infrastructure. The state’s tax structure, lower labor costs relative to California, and the proximity to Tesla’s AI training cluster Cortex 1 and 2, both located at Giga Texas and now totaling over 230,000 H100 equivalent GPUs, means the Optimus software stack and the factory producing the hardware will share the same campus. Tesla’s Q1 report also confirmed completion of the AI5 chip tape out in April, the inference processor designed specifically to power Optimus units in the field.
As Teslarati reported, the Texas facility is intended to house Optimus V4 production at full scale. Musk told the World Economic Forum in January that Tesla plans to sell Optimus to the public by end of 2027 at a price between $20,000 and $30,000, stating, “I think everyone on earth is going to have one and want one.” He has previously pegged long term demand for general purpose humanoid robots at over 20 billion units globally, citing both consumer and industrial use cases.












