How to fix Tesla Door Handles

On a mission to please his wife Car Guru shows you how to fix those faulty tesla door handles.
Thank you to camera man 1: Ev tuning solutions
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Door handle repair kit located here
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[@RichRebuilds]

Door handle rebuild kit/exchange located here evtuningsolutions.com/products/model-s-door-handle-rebuild-kit-service

[@MrBrander]

But how do you get that one nut back in there which was next to the window glass when the glass was down?

[@purge98]

4:56 No kitchen knife. I'm very disappointed.

[@johnbutler5650]

Was that a NEW harness that you tried first? I have to say that that whole door is an absolute mess from an engineering standpoint. Overly complicated with obvious “ choke point “ failures. If the wiring harness is prone to failure, why has it not been corrected by Tesla ? I have to say that these things do not impress me.

[@chriswalquist6323]

​@@MrBrander My question too! I got lucky--put a tiny piece of duct tape on the wrench to make the nut snug in the wrench, and after positioning the nut over the bolt, used a screwdriver to turn the nut as I pulled the wrench partially off. (However, getting the door handle's upper hole over the bolt took an hour! Finally had to get my headlamp and a screwdriver to work it past the window--which was all the way up per Rich's trick of tricking it into thinking the door was closed, but still a pita). The paddle gear was $6.00 at the service center. Thanks Rich!

[@xxxnorth9078]

I wanna cry this looks so didficult

[@beezy364]

You gotta think years from now, kids buying $2000 dollar Tesla will look at these diy videos.

[@NoyziNeighborz]

Bizzy jones I thought the samething

[@Northstar4653]

Won't be more than 5 years..

[@AttilaTheHun333333]

This will be the least of your problems, when you buy a Tesla for 2000 bucks.

[@LauS0]

We'll see them in third world countries pulled by horses

[@wekker090]

Doubt old Tesla's will do well on the market, the parts are bad and expensive...

[@Aikaramba12]

These videos are so much funnier than other car videos. I love your humour! Greetings from Norway :-)

[@marfrandema1884]

Kudos to the HAND model.

[@thomasjameson5761]

Just paid $300-something to fix a handle through Tesla and my 2nd one just went out. Doing it myself this time and this video is invaluable. Thank you my dude for empowering others 💪

[@gbw28]

I don’t even own a Tesla but here I am watching the door handle to one being fixed. There is something about watching people repair and build things that is intriguing and somewhat motivating.

[@joewilder]

I'm amazed how much you know about these things. I would think you would have had to messed with them for years to accumulate that much information. Good video.

[@iMadrid11]

Here’s a tip. Anyone can buy a “Service Book Manual” for any production (car, truck or motorcycle) make and model.

[@ninjamaster3453]

Chris Bautista do they sell a telsa service manual?

[@Coyote.five.0]

all cars have different mounting holes and different bolts sizes but the principle is the same and you you have your principle dial in you're good to go 👍👍👍👍

[@sdcheshire]

Thanks for posting this video. Following your instructions I fixed my broken Model S door handle in a couple of hours, and saved myself paying Tesla $550 + labor. I bought the microswitch kit from EV Tuning but didn’t even need it. I simply cut the wire at the break, stripped a bit of insulation each side, bridged the gap with about 2 inches of stranded wire (to give a bit more slack for the constant movement), covered the solder joints with a bit of heatshrink tube to insulate them, and put it all back together. If it breaks again I’ll do the full microswitch swap next time.

[@fuadkrasniqi3236]

Will it also work on a Tesla model S. In Denmark.

[@TINMAN1ONE]

Rich! I spent $6 dollars on a better built replacement part + 6 hours on the project. You saved me so much money by not having to take it to Tesla, plus I get the satisfaction of doing it myself and now I can replace the others 3 doors gears no problem. Thank you!!!!

[@davidbeppler3032]

Wife gonna be jealous when she sees you flirting with the lighting guy/hand model.

[@Dithermaster]

That's about how I did mine. I didn't have a replacement harness so I trimmed the broken wire and re-soldered it to the microswitch. For the centering of the door handle I used toothpicks to equalize the spacing while I tightened the nuts. If your 10mm wrench doesn't fit from the top, buy a "slim" version at the hardware store. I didn't know about the trick to make the window higher (but if you do that make sure to lower it before closing the door). I've also heard you can use a bladder tool to spread the internals apart a little to make more clearance for getting at the nut and getting out the handle. It took me about 1.5 hours to get my first (and so far only) handle out, 15 minutes to fix the wire, and 3-45 minutes to button it all back up. Still, less than than driving to my nearest service center and back.

[@Analkalle]

Dude your channel ist awesome and you're funny as hell. Don't even have a drivers license but I love to watch your videos.

[@BertRedd]

It may help to add some sort of silicone where the wire meets the plastic to help prevent future corrosion.

[@otofoto]

Rob Vella just fit a heatshrink tubing over the wires. Car guru fix was temporar as wires will again break of because of flexing. This is bad engineering in its greatest, the wires just need additional transitional reinforcement so it doesn't bend in one point. I drive Honda it has also breaking handles and replacement OEM is the same story.

[@rkan2]

agreed! Just don't do regular hotglue, as on hot days it will actually flow away slowly ! :D (personal experience)

[@otofoto]

rkan2 hot glue will make it worse as it may not seal entirely and water leak will kill it quckly

[@ericdodson3630]

Thank you Rich, my wife and I just got done fixing the gear in our passenger side handle (we replaced the wire too just got good measure) and if it wasn't for your video we would have had to take it to Tesla to get fixed. I love your sarcasm and humor, thanks again for all the hard work you do.

[@pietervanhoorn1977]

Thanks rich my dads 2013 model s had 2 of them fail in 1 week so he needed to get in his car from the rear seats but I fixed both of them in 4 hours

[@GerardBurkeBurkesGarage]

I follow your channel for the great info on Tesla's and I learn a lot with each stripdown/repair on them, you have a great channel that also cracks me up. I think your sarcasm is the most important part of your channel though, pure quality :)

[@JeremyNaus]

Good tutorial, only thing you missed was how you replaced the top nut, that you need to remove via the top window space. I ended up ducktaping it to the wrench 😁

[@66tbird1]

Admiring your skills. I'm way to old school for that much extra work to fix a door handle.

[@serpent77]

Ya never showed how you got that top nut on behind the glass (where ya had to roll the window down and pull the trim to access it)

[@IdeasHaveBrian]

I'd like to see how this is done too... or did you just leave it out?

[@gregcalo7957]

very praiseworthy that you tell hopefuls the potential troubles and costs with Tesla. They are a ticking timebomb. Those who fail to heed what you say will ultimately pay heartily

[@jadahutt]

You may consider adding some Loctite Dielectric Tune-Up Grease at the electrical connection points. It will help prevent corrosion. I also have a friend who keeps a deck of playing cards handy in his shop to help hold spacing on his car projects. Keep up the great work with all these videos. :)

[@dioburtophoto]

It's 2021 - watching these super old episodes shows the creative genius behind the new episodes - the transition of ideas is almost seamless - to have this happen naturally or via a script - still kudos

[@dogphlap6749]

I've done this repair a couple of times and Tesla did it once i.e. they replaced the whole mech with a new and improved one when it failed under warranty (for some reason it was always the driver's door). I've not heard of anyone drilling those holes for better access to the micro switch screws, excellent idea. Thanks.

[@roland6663]

Super appreciate how you showed us what was wrong with the door handle. great vid.

[@jerradcampbell74]

After this episode, CarGuru finally gets laid. ;)

[@BrooksBraml]

he's 1/2 way to getting laid

[@SianaGearz]

It's probably just a handjob from the hand model. AGAIN.

[@wolfhill12]

Watched multiple videos, took door apart and then realized other guys were using first generation doors handles. Watched your video-very informative and well presented-and learned how to do it correctly. Also watched segment on EV microswitch replacement and ordered one. Would rather fix it once than multiple times. Nearest Tesla is over an hour away so prefer to fix it myself anyway. THANK you

[@deavman]

I ride a bicycle, but I must know how to fix that door handle

[@Lookup2Wakeup]

me too!

[@steverodgers333]

lol

[@googadisbeotches9360]

I left the top down and the window open in a rainstorm once... My bicycling experience is miserable now...😢 teach me in ways of repair sensei.

[@jonathangwynne1917]

Great video. Thats a horrific design for a door mechanism. Beyond overcomplicated and basically designed to fail - quickly and repeatedly. But kudos to you for having the brains and patience to try to fix it.

[@h2o_dug]

Thanks you Rich! I had a bad squeak and didn't have to remove the handle, just loosened it, re-centered it, and re-tightened. Under an hour total and FIXED way less time than going to service center.

[@adobinson]

THANK YOU FOR YOUR VID!! I purchased the parts from ev tuning solutions and they were very helpful. Your advice was so valuable I really appreciate it. Cheers!

[@svetoslavganchev7633]

My man, you're Barry White in REPAIRS, you're humor is just like Barry's. Keep the speed. Take care!

[@AlexVenz]

Those door handle gaskets/covers have killed two of my window regulators... the front one, at the very least, is now glued and screwed so it won't fall off again.

[@SurferTy]

Alex Interesting. My back driver side window keeps getting stuck. Time to open it up and see if that’s the reason

[@georgepelton5645]

Great video Rich. You are THE master Tesla tech, for sure! This is very helpful for all Model S owners.

[@kitkatpona]

Thank you SO much for posting this video! This is the 2nd time I've had to fix a handle on my car and this was a lifesaver, not to mention funny! You rock!

[@PunditDave]

Thank You! I just finished repairing the passenger side front door on my 2013 model S P85+. Broken wire on the contact switch. Nasty job, especially the nut behind the door glass! Saved about $400

[@Pus1]

You should also point he harness downwards so that water runs down and not stay on the connectors. Hope this made sense

[@2breal91]

You are the man Rich. I do find it crazy though that a part that historically has outlived cars is now a maintenance item. I prefer not taking my doors apart as the higher the frequency the higher the probability of broken plastic pieces over time

[@Green__one]

The last nut remove to take out the door handle. You showed me with the window down and squeezing a wrench between the glass and the nut. I tried that, I just couldn't get it to work. I ended up finding the easier way was with the window all the way up as you had it originally, loosen the knot that holds the glass onto the window mechanism, and loosen the window lowering track from the door. Then you can lift the glass up out of the way, and move the window track sideways a quarter inch, and then you can get on to the nut from the same side as you did all the others. I also found this prevents the window and track from jamming the handle and making it hard to get out.

[@Knightairman1]

You are too funny. However, you fixed the handle before Saturday so you're getting lucky on the weekend. Lmao

[@randellhayes6686]

Great video, like the banter with your camera man.

[@71volare]

Rich, you are following the great American tradition of the Wright Bros. thomas Alva Edison and Henry Ford. I play with pre-wwII Fords and hot rods and what you do is far more complicated. Keep up the good work.

[@alexd15680]

Your channel is a hidden GEM man. You will reach 1 million subs soon if you keep this up.

[@srt4cuz]

My man uncle rich..you are the people's champ cause of you and your videos I am going to buy a CPO..thanks man keep the repair videos coming

[@JD-ce4so]

Was it fixed before Saturday night??????

[@davidbeppler3032]

probably not. faulty part.

[@ozzyfromspace]

Well, today’s Friday, so Ima go ahead and say yeah. And yes, I know why you asked lol 😂

[@ozzyfromspace]

I don’t own a Tesla, but enjoyed this episode. Lol So much engineering for so little door.

[@paulyh4531]

Float Circuit yer prob a bit over the top can't see them using them on future cars , although I prefer them to the model 3 handles they look a bit fiddly on. Videos I have seen .

[@ozzyfromspace]

+Pauly yeah, they're interesting gadgets, but I would never spec a production car with a motorized door handle, because entropy happens, parts move, and things break down. They did it because it was cool, and I get it. Fiddly is a good choice of adjective btw :)

[@xeniavader]

Great video. Watching this video gave me courage to attempt a door repair on my 2014 S85 I'm a computer guy, never worked on cars before. This job was a freaking nightmare!!! Each step I ran into new puzzles... how to disconnect the wire clips... dropping screws into the door.... I couldn't get the door handle out so removed the window.. that was scary... dam door handle mechanism is painful! couldn't unscrew the switches, drilled a hole in the side... ended up soldering the broken wire, leaving the switch attached. It then occurred to me.... I COULD MESS UP MY ONCE 89K dollar car.... I somehow managed to get everything back together.... it now unlocks 50% of the time!!!! success... . dam!!! Great little adventure. May try again!!!! One can buy the entire door handle assembly on ebay. Over a grand for Tesla to fix this... figured what the hell. LOVE ALL YOUR VIDEOS!!!!! Stroking that guy's hand on your other video was a little creepy, but a nice touch... (pun?) I'm delirious after taking my car apart.

[@paulwatsonLN]

Great video...this is how guys work together, talking smack and everything...love it.

[@Greenhornet411]

CG remember happy wife happy life. I hope she fulfilled her promise to give you some!

[@FelixMendeldog]

Fantastic video, thank you so much. One handle just failed within the used car warrantee period; this repair is in definitely in my future.

[@JamesChen94560]

Thank you very much, Rich. Much appreciated. Was able to replace my door handle by buying one on the web for less than $100.

[@ronnie44k]

I’m glad KZbin recommended me this 5 years after release while I still don’t own a Tesla!

[@darlantro]

These are edited really well, with a good sense of humor. Reminds me of Car Talk on NPR. I bet you would get along swimmingly with Ray Magliozzi.

[@mujjuman]

Rich you are such an amazingly intelligent man. Super props to u bro. You inspire me so much

[@gsxr1kmatt]

Man your videos are fantastic. Thanks for posting and keep it up!

[@scott.hanson]

You're a hero! I wish there was more DIY spirit in the Tesla ownership community...

[@jmbrangwin1370]

Saved my ass. Kit I bought from ReelDealEv did NOT have a video of drivers door. This video is the ticket. Laughed my ass off when his handed changed color.

[@R281]

Thank you for taking the time to put this together.

[@stevemurch3245]

Incredibly informative, and also hilarious. You really know your stuff. Thanks; great video.

[@KaioStryker]

On the right micro switch you need to make a loop so pressure doesn’t stay on wire right under the micro switch but across the whole wire.

[@RightToSelfDefense]

Good job. One thing I would expressly make sure to do and that is as soon as you get the handle mounted again and its bolts locked it, I would retest the door handle to make sure it sill opens the door. I would do that before you re-install all the inside door assembly and its bolts. If the door handle doesn't work just after you assemble its bolts and then you have all the inside door panel bolts, then you are going to have to take those bolts off all over again. Bravo.

[@viktorvar]

Thank you, thank you, thank you! Just replaced the harness based on your instructions today. Keep up the great work! A 30€ repair instead of 400€.

[@stefferson-ev7346]

Thanks m8. As many people think Tesla's owners are rich, they're wrong. You just save us a $2000 Tesla charge us to replace all that component.

[@alexandermiroshnychenko5771]

Actually followed this video guide and managed to fix a slightly different problem. My door handle came all the way out when I unlock the car, which opens the door right away. Had to adjust a screw next to a switch to make the door stop at a middle position. Thanks a lot, man, this video was extremely helpful!

[@veritycaruso]

I have the same problem you are having. My front passenger door opens every time the handles present. Where is the screw you adjusted?

[@alexandermiroshnychenko5771]

@@veritycaruso Oh, it was so log ago, I've already sold my Tesla, it was too much trouble being as ald as it was...Did you pull your handle module out of the door yet? I'm sure I'd recognise the adjustment screw if you take a picture of the module without plastic covers

[@veritycaruso]

​@@alexandermiroshnychenko5771 Thanks for the reply. My dad gave me his 2013 model S when he got a new one a few months ago. I was hesitant to accept it as it already had 173k miles on it. Dad said I am free to sell it or drive it. I still have my Prius and may end up selling the Tesla. I am not a car person, but I have to admit, it is a lot more fun to drive Dad's old car. Though it gave him few troubles, I figured it may be time that it would start breaking down. Sure enough, a few months later the first door handle issue occurred. I watched another video and located the screw and a sensor that determines how far the handle presents. I'm not sure if I should tighten or loosen it, but I'll try both ways and see which way fixes the issue. I haven't taken anything apart yet, but I plan to tackle it tomorrow. I hope you're enjoying your new ride. Cheers!

[@j.g.2982]

Thanks from Germany! 2nd this year your video saved my a lot of money. Good Job!!!

[@andyhuang5548]

Nice video! Just scratching my head if I should give a try… just paid $380 for the famous three beeps issue with the rear truck and yesterday got this exactly the same door handle problem… 2017 tesla model s…

[@delschier1419]

AN EASIER WAY! Rich thanks for this and all your videos. I just did failed door #2. There is an easier way than drilling holes to get the microswitch screws out! Mark the big bolt in the middle and turn it out 4 full turns making the screws accessible. Don't forget to put that screw back in the exact number of turns before you put the cover back on. The big issue I have had, and is that is not covered in any video, is how to get the connectors to release. You have to be careful of the wires and the connectors need to be examined carefully to see how they work; they don't just pull out, you will damage them. BTW the $55 stainless steel gear Amazon kit is not stainless steel and doesn't fit without some machining. Also, that kit's microswitches are a different size and mess up the adjustments if they work at all. Don't ask how I know, I had to put the original good switches and harness back in.

[@kitkatpona]

VERY good video and hilarious to boot! Thanks so much for making this.

[@purplex_purple7717]

I can’t believe that news channel didn’t interview you instead of that one dude that just fixed his car

[@nihilsin3deo]

Car Guru is smart. And funny!

[@rodwalpole8340]

Ok, new to this in austraila why so complicated tesla should rethink KISS .

[@johntheman2006]

Brilliant. My A8’s keyless door handle is faulty. I need to replace it. Instead I watched your video. Much more entertaining.

[@fredscratchet1355]

Hiya Rich, you know the more I see you constantly fixing bad designs on these cars the more I think Nah! I'm happy with my Prius. Yes I know it's not cutting edge anymore compared to modern ev's. But you know what, it just keeps going. I love your channel though so don't stop fixing them haha.

[@incognitotorpedo42]

I can't upvote this enough.

[@erogliktuort]

Awesome video. I found that I can open the door by pulling very very lightly and slowly on the handle. I expect this will stop working sometime, so very glad to have the video. After fixing, Is it possible to use silicone to encase the wire connections, to strengthen them? Thanks again.

[@yoyomo777]

Have you ever considered McGyver'ing a refreshed front bumper retrofit? Love your vids!

[@jusb1066]

only IF tesla will sell ya one, which i guess they dont wanna

[@Brutaka1]

I wasn't expecting this much work when removing the door handle. Holy crap!

[@DKdoman]

Is there a way to protect the harness from failing again? Maybe squirting a lot of glue or something, so it won't corrode?

[@MrMats0n]

I was thinking generous heat shrink tubing around that, shouldn't be too hard.

[@Spacebirdy]

I'd just install something like a Pi Zero W and make my phone become the door handle

[@Dithermaster]

It's the routing of the wire that focuses wire bending on the one place. If you work on a door handle, re-route the wire so the repetitive bending is more evenly distributed and not focused.

[@BixbyConsequence]

A gob of silicone, to provide vibration damping and stress relief where the wires enter the switch boxes. Will also seal against water intrusion. Wouldn't hurt to tack down some of that loose wire with tape or adhesive to reduce movement.

[@Maverick7r]

I don't even own a Tesla but love your videos. You seem to be such an awesome and hilarious guy, keep up the great work man!!! P.S Are those 8 inch speakers in those doors?? The sound system must sound awesome!!

[@Nahyoutrippin]

Thanks Rich. Helped me fixed my door. Followed instructions to the T

[@loz11968]

I know everyone has their hints and tips but here’s mine if this is a common failure use some Vaseline pushed into the connectors and the back of the connectors to stop moisture and prevent corrosion. Another great video thanks

[@RhettRobinson]

Thanks for the video, walked me right through it!

[@utcman]

Now all you have to do is get those snow tires on and then you’ll “GET LUCKY” lol

[@carleh2008]

see previous videos, already been done

[@fatboy19831]

This is an excellent video......lets you know that if you take this too the dealer just a few years later you may have to return for the same problem.

[@59seank]

Great video. I admire your willingness to tear apart your car and fix it. Watching this video really lowers my confidence in Tesla. Door handles should not be a problem for modern cars.

[@fredpinczuk7352]

"...my hands are now white..." Dude, you cracked me up. Great video.

[@squint0241]

Man I love your videos 😂. Informative and you crack me the hell up 🤣😎

[@my31and37]

I have no Tesla...I don't want a Tesla..Why do I enjoy your videos?

[@MontanaDoe]

4 hours for me. Got it taken care of. The tiny torx that holds the switches in place for a 2016 is T9. Had to go buy one of those

[@luisislaw]

Thank you that was nice and thorough

[@luisarmasjr]

On mine, the micro switch to the right that activates the latch opening was shorted out. Good video; thank you

[@dannybrennan31]

@7:33 "watch the whole video before you try this. I'm gonna put that at the beginning" lol

[@donell4705]

Thanks so much for this video, you made it so much easier!

[@shahbazkhanjs]

Amazing videos brother. God Bless!

[@MatthieuPesesse]

Even as a non English speaking person I laughed at the jokes during the video:D Keep up the good work bro’!

[@EastBayRiderII]

If you know they corrode why didn't you put some sealant on the connections ?

[@ChrisEpler]

Hopefully the Gen 3 handles are going to hold up better, just had one put in for my drivers side door after I started having the "eat your hand" issue.

[@WANDERER0070]

Very informative,,Id sugest to waterproof those wires by wraping some electrical tape or coat it with silicone to prevent further rusting,bc water will get there again in the future,,no doubt,,Tesla should IMPROVE on this design

[@epicscreenname989]

*THIS IS GOING TO GET A LOT OF VIEWS. GUARANTEE IT* PS don’t forget the snow tires Rich

[@NoyziNeighborz]

I saw this vid and thought... “smart man”, wifey ain’t play’n.

[@jasoncastellan8482]

Brilliant with some great humour. Not sure what your affiliation with ev tuning is, but would be great to see how much we "may" be saving on the parts purchase from them. I realize I am saving labour also, but more importantly saving the whole PITA of taking it to the shop etc is most valuable.

[@grendelum]

14:12 I found that cardboard beer coasters, professionally ripped into small pieces and meticulously placed, work exceptionally well as temporary shims to ensure the handle > door gap is consistent :)

[@derBara83]

@Car Guru, You are hilarious, crack me up every time LOL, Thank you for your videos!