Model S Door Handle Rebuild Kit
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Permanently fix Tesla Model S door handles!
New Version 2.0 Microswitch Harness!!! Heavier Gauge Wire, Silicone insulated braided wire, integrated strain relief and molded microswitch ends!
Tesla Model S Door Handle failures have been a common and aggravating issue for a long time now. Under warranty the answer is simple; call the service center, and schedule an appointment for replacement. However many cars are coming out of warranty and the replacement parts are becoming hard, if not impossible to come by. Tesla is no longer supporting the 1st and 2nd Gen door handles. This requires an expensive retrofit to the 3rd Gen handle in upwards of $1000.00 per handle. It also requires a special calibration that only the service center can perform.
EV Tuning has put together a comprehensive kit to help any DIY person to completely rebuild their door handle. The kit includes a stronger machined stainless steel gear, 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.
The paddle gear is made from machined stainless steel instead of cast. This ensures it's both stronger and more robust than the cast piece Tesla uses.
Replacement for 1042845-00-A Paddle/Pivot Gear
Original Equipment Panasonic switches from Japan were sourced.
Replacement switches for existing 1016009-00-C Harness.
Replacement hardware for commonly broken items were included to ensure you don't start the job and get stuck with your door apart.
1025401-00-A X 9 Door Panel Clips
1067906-00-A x 4 Vapor Barrier Retainers
Optional Rebuild Service
If you're comfortable with removing your door handle but don't feel confident with rebuilding it, then we can provide you with a fully rebuilt handle that you just swap out for your failed handle. Price includes a refundable $150.00 core charge when you return your old handle. Core must be a Gen 2.0 handle to receive core credit.
Our good friend Rich from Rich Rebuilds has put together a great comprehensive video on how to rebuild the door handle from scratch.