Why Tesla Door Handles Break And How To Fix Them

We explore the two main ways that Tesla door handle break and share some low cost fixes that resolve the issues.
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[@jeffkrueger7173]

Many thanks. I used this video to fix my front driver door today; it was presenting, but then continued to grunt thinking the handle was not fully extended. The root cause was two of the micro switches; both were electrically OK, but one had a loose mounting screw and one had a broken metal actuator lever. I ordered new switches (thanks for the p/n below!) and re-assembled for now. Works!

[@cardrag]

Easy to take door apart?

[@randycarter2001]

The big problem with the switches is the wiring was not properly engineered. Where the wires exit the switch is a high stress point. The wires should be attached to handle frame and routed to a point of minimum movement. You do the reroute when the car is new and they last forever. I believe there is tech bulletin about the switches and the wire reroute.

[@Rick9482]

That has got to be one of the biggest scams in the auto industry. $700 plus on an assembly that doesn't have a chance of lasting anywhere near the lifespan of the vehicle. One of Tesla's biggest mistakes and was definitely a factor in me not buying a Model S. Really good video that should save quite a few people some money.

[@Datacorrupter234]

same just too many tiny engineering problems is keeping me away from owning one i dont wana deal with all this unexpectedness when i could just buy a camry etc that you can count on

[@Rick9482]

@@Datacorrupter234 I ended up with a M3 Dual Motor delivered last day of 2020 in perfect condition and continues to stay that way. Very cool car to own and drive, it's just superior.....period. My year of free charging is now over but my charging fee is still pretty low. Driving an EV is quiet and comforting. However, I'm quite appalled at the price increases. Definitely puts it out of buying contention for most families.

[@dogphlap6749]

+Boost Brothers What a fantastic video. I've had one door mechanism replaced under warranty and the service guy was kind enough to give me the old mechanism to play with. It was a micro switch failure. The rack and pinion failure mode was news to me. One point not mentioned here is the fact that all four of the Model S door mechanisms are different. That was a strange design decision as was the choice of mounting the micro switches on moving parts rather than on the stationary part and using the moving part to operate the switch, a decision that meant the wires to those switches were flexed, eventually leading to failure of the micro switch sub loom. Anyway thank you so much for this video.

[@cosmintuchi]

I think TESLA want to make money from maintanance

[@mucall]

Thank you for this video. Once out of warranty this will save the day. A+++++++ Quick update. I had 3 doors fail this pass year under warranty. With this videos lots of savings for us.

[@BoziTatarevic1]

You're welcome, thanks for watching Julio.

[@jimmywinskowski5489]

Did you order the part(s) directly from Tesla? Was it the wires or the paddle gear?

[@marcannemariebintner1473]

Hi great video and very helpful! Don’t want to spend unnecessarily and against replacing everything when it could be repaired…. Where can we find the switches???

[@Dgboss78]

Thanks a lot for your video and the links in description. I was able to fix my door handle for 78€

[@fowlercarlos]

I had to replace all 4 of my door handles at some point after the warranty expired. Spent nearly 4 thousand to have them replaced by Tesla. They upgraded mine to the 2nd generation handles, since they claim they had a lot of issues with the 1st generation handles. I will definitely save this video and try to do the repair myself if they ever fail in the future.

[@condor5635]

Carlos Fowler - I can’t think of much I’d rather spend $4000 on. Thanks for confirming why I don’t want a Tesla

[@christianorness2690]

A very informative video. My driver door handle stopped presenting itself today. I’m pleased, but also not pleased, to learn how it broke. Thank you much for filming this!

[@paramn604]

Excellent video...very helpful. Is it possible to replace the interlink position sensor shown towards the end? The wires coming out from my unit have broken off..

[@robertsteich7362]

As a formal slot technician. I can see the headache in the optic sensor and micro switches. One manufacturer comes to mind, IGT. They used both, and both were in series for the door. The micro switches were placed so that when the door was shut, the switch was closed. But there was one more thing to be done. That was to push down on the latch to engage the lock. Of course the optic sensors was on this large latching system. And if the optics did not like up, the slot machine wouldn’t see a door closed. They were a major PITA because you couldn’t tell if it was the optics not lining up, not working or the micro switches not lining up or working. All because it was in series and the slot machine only saw open or closed.

[@moestrei]

Hi Boost Brothers, there are 2 different types of micro switches used here: One with and one without lever. Your link points to the Panasonic micro switch without lever but it would be more sensible to point to the one with lever which is Panasonic ASQ10418. This way you just have to order/stock one type of switch because the lever is easily removed to convert to the non-lever type (which is Panasonic ASQ10410).

[@DavidDrivesElectric]

awesome video. That last sensor is a press sensor that makes the handles present if you slightly push on the handle.

[@jonathanpullen7439]

Should have used optical sensors instead. And had the wired portion not flexing.

[@Xetairex]

Thank you so much for this video. With this video and another to take out the handle, I had much help replacing my broken paddle gear on the 2013 Model S 60 KWh. I agree with other commenters that this is overly complex, and prone to breakage due to multiple points of failure. Bad design, I’m sorry to say.

[@gerhardsommer6973]

Thank you for this video! Which part is borken, when the door handle do not present after pushing it? But the door handle presents when I press the fob.. Thx

[@don.poulson]

Thanks for the video.

[@scottperry7487]

I had a microswitch failure and Tesla came to my house, replaced the entire relay and replaced the gear (which was still working) with an upgraded part for about two hundred bucks

[@harry-eto]

Oct. 2022: Tesla offered to repair it for $ 430 with a mobile technician. However, the paddle gear is available from Tesla for $6 and i will do it myself. Should be a V3 Handle but still broke after 18 months.

[@birgittasegerstrom8953]

My handle did not retract - but only occasionally. In such cases the door closed and locked as it should and it was possible to open the door with the handle. Usually (but not always) the handle retracted as it should the next time. I have installed a new harness with the 2 microswitches. Still the handle stays out occasionally. I can not see anything systematic in the behaviour. Any suggestion what could be the problem?

[@franklora17]

Hi there thank you for your videos I’d like to know where are you located because I have the same problem with one of my doors. Please let me know if you are near to call you to see if you can fix it and how much you charge for thank you very much and God bless.

[@wenbiaoliang]

It seems the wires, electric contact point are not water proofed, what if water, ice or sand got in and contaminated the contacts? Seems like a design for interior electronics, not for door parts?

[@Damien.D]

Wenbiao Liang you are totally right, it is mostly of the shelves parts for household products, and it's definitely not made to last long. A pity for a 100k bucks would-be high end green car...

[@Xetairex]

Actually the door handle assembly has a rubber gasket to protect against water intrusion.

[@Damien.D]

Overengineering at its finest. Add some low quality sourcing for materials, parts, wires, components, and you have a regular maintenance nightmare.

[@jakWiize]

That was awesome! I'm assuming that main bolt can be screwed in our our in the center to change the testing position of the handle when retracted?

[@tjxoom1]

My door handle works fine. Except the pressure sensor does not work. When I press the handle it won't present. Is it the sensor with the module that needs to be replaced. I have to hit park to extend then pull the handle to open the door. Thanks

[@angelvaca9232]

what is the characteristics of the motor? (rpm, is a step motor?) to buy an aftermarket ..

[@danielkool5752]

Mine (classic) is opening the (rear door behind the driver side) door automatic or random have not find out when or why...... is that also a microswitch issue?

[@rodchapin8706]

Yes, its probably poping the door right after presenting. One of the two microswitches on the handle tells it its presented. The other tells it was pulled on and to pop open the door. Usually the wire breaks open and you cant get in, for your case maybe shorting. The third switch on the cog tells it the handle was pushed on for re-presenting the handle.

[@brndumsautoservice8680]

Where is the link to the man who sells the metal item to present the handle

[@flixbue6565]

The small metal piece is actually worth 6€, got it from an official Tesla service center in Germany during a personal visit

[@thetraindriver01]

Great video, thanks for the effort 👍👍👍

[@KaioStryker]

Very good video. Thanks man!

[@Yoneldelar]

How does this door handle go about pulling the door cord so it unlocks?

[@hondofourfivetwo9347]

It’s easier if you release the springs to remove the rod, also on the paddle gear they have bushings as well this example they probably disintegrating when the paddle gear broke. They are thinner than the other bushings used throughout the rest of the unit but same inner and outer dia. Also loosening the center bolt allows easier removal of that inner switch on the fork This example is a very early version and yes they are a horrible design the 2.0 version has the same issues (same parts internally) informative video otherwise

[@jackylsmith8138]

Looks like they hires some 1980’s GM engineers for that handle.

[@yolandathomas7862]

I want to do a Tesla door handle swap on my 81 Cutlass do you think it's possible to get the door to pronounce and open with the hardware inside my car

[@Speedytrip]

Sad that 4 years later, some new model S Plaid still seem to have door handle malfunctions.

[@dasppg9737]

Does anyone know how to permanently disable the handle (moving in and out) so I could just press in to release the door instead? I love the model s but this design is over complicated and too problematic for simply opening a door

[@yolandathomas7862]

and if so can you give me some tips on how I should wire it up

[@GregSr]

I don't own a Tesla - but I'd love to. I keep my cars way past warranty. The flimsy design of the Tesla door handles reminds me of the pop-up headlights on both of my Corvettes (1988 and 2003). I hope the rest of the Tesla was designed better than the door handles. I've been wrenching on my cars since the early seventies. The Tesla door handles look like a great idea that was poorly executed. My son has ordered a Tesla but won't get it for another 6 months. Hopefully, the door handle design will be improved by then.

[@ciumoiucucaca]

someone repaired the handle and replaced the wires with silicon wires, he said the stiff wires really can't handle the amount of door openings

[@SimonChampa]

Great video and what a stupidly over complicated door handle.

[@nickthompson7369]

They probably don't want you working on it yourself or want you to replace they whole thing

[@GimpyMR2]

Firstly I appreciate the video, I've been researching DIY repairs on these cars since I'm considering one as a daily driver. I knew the handles were a common issue. I just have to say... That part looks really cheap and not designed for the Long haul. I hope the rest of the car isn't like this.

[@pmacafee]

Can I replace a Generation 1 handle with a Generation 3 handle?

[@BoziTatarevic1]

I believe that going to the newest generation may require programming by Tesla.

[@pmacafee]

@@BoziTatarevic1 Thanks

[@user-jm5lf8vw6g]

Thank you for the story about this part. I have the opportunity to make such a part from aviation aluminum, since what is done at the Tesla plant and in Europe from selumin is not a very strong part and the price of such a part will be $ 55 if the order is from 20 pcs. We can make stainless steel, but it will be more expensive, under a separate order. Best regards, your subscriber from Moldova, Vladimir. Спасибо за рассказ про эту деталь У меня есть возможность делать такую деталь из авиационного аллюминия, так как то что делают на заводе "Тесла" и в Европе из селумина, не очень прочная деталь и цена такой детали будет 55 доллоров США, если заказ будет от 20 шт. Мы можем сделать из нержавеющей стали, но это будет дороже, под отдельный заказ. С уважением, Ваш подписчик из Молдавии, Владимир.

[@stevesurf22]

You can now buy a stainless steel paddle gear from Tesla.

[@JosephdiCaro]

What a piece to fucking make cast chinesium lol

[@genekelly8467]

Replace a simple lmechanical handle with a motor, switches, gears, actuators..stupid

[@zaneh6224]

What a ridiculous complicated mechanism just for a door handle

[@nickthompson7369]

They fold in and out for aerodynamics, but I don't know how much they help

[@Xetairex]

I agree. I am replacing my paddle gear right now, thanks to this video.

[@ChrisEpler]

Gen 3 handles are now out which use a hall effect sensor, they are a LOT less complicated, the micro switches are gone. No giant harness rats nest.

[@fredpinczuk7352]

Hate to say it, but its really a piss poor design. With the frequency of failure and a decent third party engineering report. I think there is ground for a class action lawsuit. At minimum it could force Tesla to extend the warranty for an additional 5 years or more. Or make the repair part free to replace. Simply having wires on a microswitch fail would indicate its the wrong wire for the application, and its installed without proper strain relief on a moving hinge. That alone is an easy win. The piece that is cast is more than likely under-engineered, and requires a higher wall thickness, or machined out of a solid block. Also noticed there is zero grease or lubricant visible on the pinion gear assembly. A good lawyer can really make money off of this one.

[@terjetytland884]

So much switches and cables just for a hande. It will have many issues to come. Make a fully mecanical hack handle and simplyfie it😁

[@Pequin1000]

Looking at the inside of that door handle, I must question quality!

[@ap4709pk]

This is what I hate about Tesla, it’s filled with this gimmicky garbage that fails often. How about a manual door handle which is proven to work instead of this crap. I really want a Model S but stuff like this makes me hesitant.

[@Northstar4653]

Good video. Tesla overpriced junk..

[@amirbaniassad3052]

It is flawed design by Tesla and poor owners have to pay thousands of dollars to fix Tesla’s mechanical design failure. They should have a recall and fix this for free, otherwise they get a class action sooner or later. Or if it failed they should fix it for free, since a recall will cost them hundreds of millions. 3 of my doors have failed and no warranty.

[@bbbf09]

Read Elon Musk's biography. This was apparently his insistence that these dumb things went in against advice of wiser heads. It then seems they put either (a) newby or (b) a not very good designer or (c) saboteur in charge of realising his 'vision'. Moving microswitches - way to go whoever you are who designed these in. It does make think about my thinking about buying a Tesla.

[@rroge5]

people that buy new tesla probably want to give money to tesla... Probably want to pay tesla for their expensive repairs , far better than giving money to regular car dealers for expensive repairs.

[@pashko90]

Why?

[@themondoone6316]

It breaks because tesla engineers have no concept of efficiency in design. The more parts the more chance to break.