Replacement of both left and right headlight assemblies on a 2024 Tesla Cybertruck Cyberbeast. The Cybertruck uses a full-width front light bar plus separate lower headlight modules; this procedure covers the lower projector headlight units secured behind the front fascia/wheel liner access points.

Warnings

Tools required

Parts

• Front headlight assembly, left (driver) × 1 — Tesla Cybertruck OEM left headlight assembly — match by VIN
• Front headlight assembly, right (passenger) × 1 — Tesla Cybertruck OEM right headlight assembly — match by VIN
• Push-pin retainers / fascia clips × 10 — OEM-spec replacement fasteners (clips often break on removal)

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Exit ALL doors with the key fob/card away from the vehicle. Wait at least 2 minutes for HV systems to fully de-energize, even on this non-HV job.
3. Disconnect the 48V low-voltage battery per Tesla Cybertruck service procedure (location and connector type differ from 12V Teslas — refer to the Cybertruck service manual for the 48V battery access location).
4. DO NOT touch, cut, or pierce ANY orange cable — these are 800V and lethal.
5. If at any point you encounter an orange cable, an HV component, or are unsure if a system is de-energized: STOP and consult a Tesla-certified technician.
6. Place the vehicle in Transport/Service mode if possible BEFORE disconnecting the 48V battery, to lower air suspension to service height and prevent self-leveling.
7. Mask the front stainless exoskeleton panels and hood edge with low-tack tape and microfiber to prevent scratching during fascia work.
8. Allow the headlight assemblies to cool fully if the vehicle was recently driven — internal LED modules retain heat.
9. Identify left and right replacement assemblies and verify they match the VIN before beginning removal.

Procedure

1. 1

   Raise vehicle and remove front wheel liner access panels
   Raise the vehicle on a lift rated for Cybertruck weight, using Tesla-specified lift pad locations. Turn the front wheels to gain access to the front wheel well liners. Remove the forward fasteners and clips from each front wheel liner to expose the rear-side mounting fasteners of the headlight assemblies.
   ⚠Use only Tesla-specified lift points. The Cybertruck's exoskeleton load paths differ from a unibody — incorrect jacking can deform structure.
2. 2

   Remove front fascia retainers as required for access
   Working from underneath, remove the lower fascia push-pin retainers and any Torx fasteners along the lower edge of the front fascia that secure the fascia near the headlight openings. Plan to replace any clips that break on removal.
   ⚠Do not pry the fascia against the stainless exoskeleton. Pull straight and release clips with a plastic trim tool.
3. 3

   Release fascia / access the headlight mounting tabs (driver side)
   Carefully pull the front fascia outward at the driver-side headlight area only as far as required to expose the headlight assembly's outboard and upper mounting tabs. Support the fascia — do not let it hang on its harnesses or sensors.
4. 4

   Disconnect driver-side headlight electrical connector
   Locate the headlight harness connector at the rear of the assembly. Release the connector position assurance (CPA) lock, then depress the primary latch and pull the connector straight off. Do not pull on the wires. Inspect the connector and pins for corrosion or damage.
   ℹ️The Cybertruck's 48V architecture uses different connectors than 12V Teslas — verify pin condition before reinstalling.
5. 5

   Remove driver-side headlight mounting bolts
   Remove the headlight assembly mounting bolts from the upper, outboard, and inboard mounting tabs. Support the assembly as the final fastener is removed. Withdraw the headlight forward and out of the vehicle.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
6. 6

   Inspect mounting points and harness
   Inspect the mounting tabs on the front structure for damage or corrosion. Inspect the harness, grommets, and any ground strap routed near the headlight. If a ground strap is present at the headlight mounting bracket, ensure clean metal contact during reinstallation.
   Torque spec

   Ground Strap Bolts12 Nm (9 lb-ft)
7. 7

   Install driver-side replacement headlight assembly
   Position the new headlight assembly into place, aligning all mounting tabs with the structure. Hand-thread all mounting bolts before final torque to ensure proper alignment with the fascia. Final-torque the headlight mounting bolts to specification.
   ⚠Verify alignment gaps to the fascia and front light bar BEFORE final torque — misalignment cannot be corrected after the fascia is reinstalled.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
8. 8

   Reconnect driver-side electrical connector
   Plug the harness connector firmly into the new headlight until the primary latch clicks, then engage the CPA lock. Verify the connector is fully seated.
9. 9

   Repeat steps 3–8 for the passenger-side headlight
   Perform the same fascia release, disconnect, removal, inspection, installation, and reconnection sequence on the passenger-side headlight assembly. Use the same torque specification on the mounting bolts.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
10. 10

    Reinstall fascia and wheel liners
    Reseat the front fascia, ensuring all clips and alignment tabs engage. Install all fascia fasteners, replacing any broken clips with new OEM-spec retainers. Reinstall the wheel liner fasteners. Torque any threaded fasteners to OEM specification — refer to Tesla Service Manual for fascia fastener values not listed.
    ⚠Do not overtighten plastic fascia fasteners — strip-out is common.
11. 11

    Reconnect 48V low-voltage battery
    Reconnect the 48V battery terminals per Tesla Cybertruck procedure. Torque the battery terminal bolts to specification. Do not overtighten — terminal damage is irreversible on the Cybertruck's battery hardware.
    ⚠Confirm you are torquing the 48V terminals to the verified value — not a 12V spec from another Tesla.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all fascia clips are fully seated and gap lines are even with the front light bar and stainless panels.
2. Reinstall and torque any wheel liner fasteners removed for access.
3. Lower the vehicle from the lift.
4. Remove protective tape and microfiber from the exoskeleton.
5. Reconnect the 48V battery and allow the vehicle to wake fully (may take 30–60 seconds).

Verification

• Power the vehicle on. Cycle low beams, high beams, turn signals, and DRLs on both sides — verify all functions on both new assemblies.
• Check the touchscreen for any lighting-related alerts, DTCs, or 'Headlight Fault' messages. The vehicle may auto-detect new modules, but a Tesla service tool may be required for full coding/calibration on some builds.
• Verify auto-leveling and adaptive headlight functions operate (if equipped) — these may require a calibration drive cycle.
• Perform a headlight aim check against a target wall at the manufacturer-specified distance; adjust per Tesla Service Manual procedure if aim is out of spec.
• Inspect fascia gaps and headlight-to-light-bar alignment in daylight; re-shim/re-align if needed before considering the job complete.
• Road test at low speed and confirm no rattles from the front fascia area.
• Note: This job does not affect any Tesla scheduled service interval (brake fluid 2 yr, cabin filter 2 yr, gear oil ~12,500 mi initial then 25–50k, coolant inspection 4 yr/50k). However, while the front end is apart, it is a good opportunity to inspect washer fluid lines and front sensor cleanliness.

More procedures for this vehicle