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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 now out of warranty and the replacement parts are becoming difficult, if not impossible to come by. Tesla no longer supports the 1st and 2nd Gen door handles. This requires an expensive retrofit to the 3rd Gen handle in upwards of $1000 per handle. It also requires a special calibration that only the service center can perform.
Our friends at EV Tuning have put together a comprehensive kit to help a competent 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.
Note: Drop ships from manufacturer in New Jersey, please allow a few days for dispatch before shipping begins.
Please watch the videos on the Installation tab below to determine if you're up to this job, since it does require the removal of the interior door panel.
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 hardware for commonly broken items were included to ensure you don't start the job and get stuck with your door apart:
This is obviously quite an involved process, but since Tesla charges $1000+ for a single handle replacement, it's worth some of your time to at least watch the videos to see if this is for you. First up, Rich Rebuilds on how to remove the handle assembly:
And here's EV Tuning's detailed video of how to rebuild the handle: