Tesla Roof Bar Installation Problem

Bought a Tesla Roof Bar kit for my Made in Shanghai 2022 Model Y RWD.
Should be an easy installation, however the metal retainer under the glass roof in two of the four locations are in the wrong position. This prevents me inserting the clips that hold the roof bars from being inserted under the metal retainer.
I’ve taken the car to Tesla Service at Chatswood in Sydney on two occasions so far and each time the car has come back with one or two of the metal clips installed under the glass roof, not under the metal retainer.
Tesla Service don’t believe there’s any problem so I made this video to demonstrate to them just what the problem is.
Unfortunately, I suspect that this is going to require some serious surgery to my car to rectify. It may be easier and safer for the glass roof if I just forget about the roof bars.
Also, these cars are assembled and spot welded by computer controlled robots. I would not be surprised if this problem of misplaced metal retainers under the glass roof turns out to be not uncommon.
I would urge anyone installing roof bars on a Tesla to very carefully follow this bit of advice from the Installation Instructions:
“Remove the clip tool (1), being sure the clip (12) is engaged in the metal receiver under the glass.
Pull up and wiggle to be sure it’s properly engaged.
Be sure the center of hook aligns with the arrow”
When you wiggle the clip as suggested, the clip should freely move about a centimetre left and right and a few millimetres up and down.
If it moves more than that, it’s not under the metal retainer.
If you can’t move it at all, something else is wrong.
There’s a gap in this video where I removed the roof bars and the rubber feet. They are all ok and it was not necessary to show them or their removal. These metal clips shown in this video are as they were installed by Tesla Service at Chatwood. The metal clips themselves are ok. The problem is the location of the metal retainers under the glass.

[@dandoupi]

Thank you, that’s very helpful and detailed

[@Martke]

Dear Stephen, thank you very much for taking the time to document and share your experience with this issue. I have exactly the same problem (Model Y 2022, Shanghai). Thanks to your video i was able to understand it and could manage to install it correctly by very (very, very) gently dilating the metall. It fits a bit tighter than the other sides but well now. Greetings from Switzerland 😊

[@user-rq8sc1eb9j]

Hi Stephen, I had the same problem on my front drivers side, and had booked it into my service centre. I wasn’t at all confident they would fix the problem, certainly not in the timeframe that we needed for our holiday. Your video really helped me understand the issue, and with a little bit of gentle persuasion with a screwdriver, I managed to widen the gap just enough for it to sit in properly. I have cancelled the appointment with the service centre, and now have two perfectly aligned roof bars! A massive help, thanks for the taking the time and for all the detail. 😁

[@arnebartels3367]

I had this problem as well and cracked my roof glas today… same position front left. Should have seen your video before, not after 😢

[@ChadMagiera]

Thanks for posting your info for others to check out! I’m trying to get my rack on today and it’s not all that smooth sailing as of yet. Cheers

[@rickbrown3504]

Thank you for sharing this valuable information Stephen and taking the time to document it for others. Other should confirm the clips are installed properly by using the methods you demonstrated in this helpful video. In researching the installation of Tesla roof racks on the internet I found some folks who had their glass roof crack when using the Tesla OEM rack. Some people commented that the clips were installed wrong by the owner. It appears you found that Tesla has some quality control issues with the bracket installation which causes owners to believe they installed the clips properly, but in fact, installed them above the brackets causing the clips to put force against the glass roof and cause the glass to crack. Good thing you are diligent in checking the dealer's installation! At this point I think I will install a Stealth trailer hitch (hidden when not in use) and use hitch mounted cargo box and other accessories rather than use the OEM rack. The hitch mounted option also has less wind drag so there is less reduction in range. You might consider the same.

[@djtaylorutube]

I had the same thought and also about a hitch mounted box if I need it.

[@CaptainSeafood]

Best video out there . Very informative . ❤

[@stephenthompson1663]

I made this video a little over two months ago. This video finally convinced Tesla “Service” that there was a problem with the metal “receiver” brackets under the glass roof. That was after two previous visits to Tesla “Service” where they assured me that their most senior service technician had installed the clips and the roof bars correctly. Finally they believed me that there really was a problem. Then: 1. They told me that they would take the roof off, fix the problem with the “receiver” brackets, then put the roof back on. They told me that I could pick up the car the next day, after the new seals on the glass roof had time to cure. 2. Phone call, it would take three days, not one day. 3. Phone call, it will take three weeks to order parts and a week to fix. 4. Phone call, it will take longer because the repair shop hasn’t done this repair before and they’ll have to get instructions from the factory. 5. I contacted Tesla “Service” a week ago to check progress. The repair shop haven’t completed the repair, but they have removed the lining and some of the interior. Should be finished real soon. 6 I contacted Tesla “Service” today. I was advised that the repair shop has completed the basic repair and they now have to repaint the affected area, then reinstall all the interior parts that they removed. That will take at least another week. Then the car will go back to Tesla “Service” where they will reinstall the glass roof. Today marks three months since I first reported this problem to Tesla “Service” and six weeks since I left my car with them. Looks like it’s going to take at least another two weeks before I see my car again, but still no guarantees.

[@ZoranAUS]

Damnit, I just know this is the path I'm going to have to take also.

[@erhantimur]

I have the same issue with the passenger side receiver, thanks for making this video and documenting. I have a mobile technician visiting tomorrow to take a look at my car.

[@erhantimur]

I'm based in London, Model Y from Shanghai

[@Nintendomac]

Ouch that sounds rough, I hope they provided you a loaner car. I had a paint repair service that took weeks longer than they anticipated. Had to twist thier arm a bit until they gave me a loaner (resentfully I might add)

[@stephenthompson1663]

@@NintendomacThey did give me a loaner M3, but my business was totally inactive for seven weeks because I couldn’t use the M3 as it was not registered and insured for Hire Car work.

[@ZoranAUS]

Same here, was just about to rig the car Model Y RWD (MIC) with racks, can only install two of my J hooks.. mind you I also have a model 3 and a set of racks for that too, I can install that with my eyes closed everytime. Looking under the rubber seal I can clearly see that the pocket for the J hook has been crimped too close to together so the hook physically will not go in... now my road trip has been compromised with just a few days out. Dealing with Tesla is fast coming like dealing with an Apple Store "Genius", they won't actually be able to do anything aside from from spitting silly quips like "with-in spec"... sorry pretty livid right about now.

[@stephenthompson1663]

If the clips wont go in correctly then it’s clearly not “within spec”. Keep pushing. Which city are you in?

[@ZoranAUS]

@@stephenthompson1663 Melbourne, fixed one of the points with a spreader tool and some precise percussion, once I get the fourth fixed I’ll put on the rack kit (hopefully) and use the torsion from the j-hooks to bend them up a bit more before dialing back down to standard torque specs. I barely trust Tesla Melbourne to change my tires (been burnt before) let alone leave the car with them for an extended period. Definitely keep this video up as reference point for others to see.

[@ctuna2011]

Just had a problem similar to this today . Had Tesla come by and they couldn't install it. Glass is offset to one side . I watched this video last night and when Telsa tried to install but could not the bells went off. On one side the bracket goes in easily on the other can't be forced in.

[@stephenthompson1663]

Is your car a Shanghai built Y?

[@sakkievanniekerk5648]

What was the final outcome or fix? I’ve just tried to install my roof racks and noticed the front drivers side bracket receiver is completely off target from where the alignment arrows on the roof are. There is no way I can fit the bars like this so I’m dreading a long battle with Tesla for a fix.

[@stephenthompson1663]

Tesla Service finally agreed that it was a problem. Long story short, they removed the roof and most of the insides of the car, all trims, seats, screen, etc…, then sent it to a smash repair shop. The smash repairer then cut out the wrong parts and welded new parts, then repainted. Tesla Service than refitted all the parts removed. The whole exercise took seven weeks.

[@sakkievanniekerk5648]

@@stephenthompson1663 ohh my what a drama. Looks like I’m in the same position. Thank you for the information

[@MarsOzzie]

Tell Tesla to put new glass with correct gaps both sides so you can put your roof rack

[@stephenthompson1663]

The glass is positioned correctly. The difference in the gap all round differs by only 1 mm. The problem is the position of the metal receivers for the clips under the glass.