Replacement of a front headlight assembly on a 2024 Tesla Cybertruck. The Cybertruck's stainless exoskeleton and 48V architecture require care around fasteners and connectors that differ from earlier Tesla models.

Warnings

Tools required

Parts

• Front Headlight Assembly (Cybertruck-specific, LH or RH as required) × 1 — Tesla OEM Cybertruck headlight assembly — verify side and trim level via VIN
• Replacement push-pin / trim clips (as needed if damaged on removal) × 1 — Generic OEM-spec body fastener clips

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Exit ALL doors with key fob 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 (Cybertruck uses a 48V LV system, not 12V — confirm location per Tesla Service Manual before disconnecting).
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage 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 soft fender covers along the front exoskeleton edges to prevent scratching the stainless surface.
7. Tape over the front fascia edge adjacent to the headlight opening with low-tack painter's tape.
8. Verify replacement headlight is the correct side (LH/RH) and matches VIN-specified trim/configuration.

Procedure

1. 1

   Access the headlight area
   Open the frunk and remove any frunk trim panel fasteners required to access the upper headlight mounting points. Use plastic trim tools to release clips — do not pry against the stainless exoskeleton.
2. 2

   Remove fascia / cover fasteners as required
   Remove the manufacturer-specified cover screws and any push-pin clips securing the upper fascia or wheel-arch liner edge that overlap the headlight assembly. Set fasteners aside in labeled order.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Disconnect headlight electrical connector
   Locate the main headlight harness connector at the rear of the assembly. Depress the locking tab and pull straight back — do not pull on the wires. On 48V vehicles, expect a different connector keying than legacy 12V Teslas; do not force.
   ⚠Confirm 48V LV battery is disconnected before unplugging — 48V arcs more aggressively than 12V.
4. 4

   Disconnect headlight ground (if separately bonded)
   If the assembly has a separate ground stud bonded to the body structure, remove the ground bolt and set the ring terminal aside. Note orientation for reinstallation.
   Torque spec

   Ground Bolt14 Nm (10 lb-ft)
5. 5

   Remove headlight assembly bolts
   Remove the headlight assembly mounting bolts (typically 3-4 bolts around the perimeter of the housing). Support the assembly with one hand as the last bolt is removed to prevent it from dropping into the fascia.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
6. 6

   Withdraw the headlight assembly
   Carefully pull the headlight straight forward out of its locating pockets. The assembly indexes onto manufacturer-specified locating pins — do not twist or pry, as this can crack the housing or damage the exoskeleton edge.
   ⚠Stainless exoskeleton edges can scratch the headlight lens — keep the lens face away from the body during removal.
7. 7

   Transfer any reusable hardware
   If the new assembly does not include adjuster hardware or alignment grommets, transfer them from the old unit. Inspect adjuster screws for damage before reuse.
   Torque spec

   Adjuster Screws3 Nm (2 lb-ft)
8. 8

   Install new headlight assembly
   Align the new assembly with its locating pins and seat fully. Hand-thread all mounting bolts before final torque to ensure the housing is not stressed. Torque mounting bolts to specification in a cross pattern.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
9. 9

   Reinstall ground and connector
   If applicable, reinstall the ground ring terminal to the body stud and torque to specification. Reconnect the main headlight harness connector — listen for the locking tab to click fully home.
   Torque spec

   Ground Bolt14 Nm (10 lb-ft)
10. 10

    Reinstall covers and fasteners
    Reinstall any cover panels, frunk trim, and wheel-arch fasteners removed for access. Torque cover screws to specification; do not overtighten plastic-threaded fasteners.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Reconnect the 48V low-voltage battery and torque the terminal bolts to specification.
2. Close the frunk and confirm latch engagement.
3. Remove protective tape and fender covers from the exoskeleton.
4. Allow the vehicle to fully wake and complete its bus initialization (1-2 minutes) before testing lighting.

Verification

• Power on the vehicle and cycle through low beam, high beam, DRL, turn signal, and cornering/auxiliary functions for the replaced side. Confirm all functions match the opposite side.
• Check the touchscreen for any lighting-related alerts or 'Headlight system needs service' messages. Clear any transient faults by power-cycling.
• On a level surface 25 ft from a vertical target (or with a headlamp aiming machine), verify horizontal and vertical aim. Adjust via the manufacturer-specified adjuster screws if needed.
• If the Cybertruck uses adaptive/matrix beam features, verify the camera/lighting calibration is not requesting a recalibration on the touchscreen — if it is, a Tesla-certified shop with Toolbox is required to complete calibration.
• Inspect the seam between the headlight and surrounding exoskeleton/fascia for even gap and proper seating.
• Note: this job does not coincide with a Tesla scheduled service interval, but it's a good time to inspect cabin air filter (2-year interval) and brake fluid age (2-year interval) if due.

More procedures for this vehicle