Headlight Assembly

Replacement of a front headlight assembly on a 2024 Tesla Cybertruck Dual Motor. Access requires removing the front fascia trim/wheel arch liner edge to reach the assembly mounting bolts; the Cybertruck's stainless exoskeleton means extra care to avoid scratching the brushed panels.

Warnings

Tools required

Parts

• Front headlight assembly (Cybertruck-specific, LH or RH as applicable) × 1 — Tesla Cybertruck OEM headlight assembly — verify side and trim level via VIN
• Replacement plastic push-pin retainers (in case originals break on removal) × 6 — OEM-equivalent fascia/liner retainers

Preparation

1. Park on level ground, place in P, engage the parking brake.
2. Exit ALL doors with the key fob/phone key 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's documented procedure for Cybertruck — note this is a 48V system, not 12V; terminal hardware and torque differ from other Teslas.
4. DO NOT touch, cut, or pierce ANY orange cable — these are 800V high-voltage and lethal on this platform.
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 fender covers over the front stainless panels and hood edge.
7. Confirm replacement headlight assembly matches side (LH/RH) and VIN-specified trim before removing the original.
8. Turn the steering yoke to provide access to the inner wheel arch on the side being serviced (steer-by-wire — yoke moves independently; do this before disconnecting 48V if possible, or move the wheel manually after with vehicle off).

Procedure

1. 1

   Open frunk and access front-end fasteners
   Open the front trunk (frunk). Remove the frunk trim/scuff panel as needed to expose the upper headlight mounting bolts and any fascia retainers along the top edge. Use plastic trim tools — do not pry against stainless.
   ⚠Do not pry against the stainless exoskeleton edges; use the plastic trim only as leverage points.
2. 2

   Remove wheel arch liner edge for fascia access
   Turn the front wheels to gain clearance. Remove the forward push-pin retainers and Torx fasteners securing the front edge of the wheel arch liner on the affected side. Pull the liner back enough to access the side fastener of the front fascia/headlight bracket area.
3. 3

   Release fascia or trim covering the headlight perimeter
   Per the manufacturer-specified procedure, release the fascia trim or light bar trim that overlaps the headlight perimeter. Work slowly along clip lines with a plastic wedge tool. Do not force — if a clip resists, locate and release the underlying fastener first.
   ⚠Cybertruck front trim clips are not the same as Model 3/Y. Forcing them will break the assembly's mounting tabs.
4. 4

   Disconnect headlight electrical connector
   Locate the headlight harness connector at the rear of the assembly. Depress the locking tab and disconnect. Inspect the connector and pins for corrosion or damage. Set the harness aside so it cannot be pinched during removal.
   ℹ️Cybertruck headlights use a multi-pin data + 48V power connector. Do not attempt to back-probe or jumper pins.
5. 5

   Remove headlight assembly mounting bolts
   Support the headlight assembly with one hand. Remove the mounting bolts securing the assembly to the front structure (typically upper, side, and lower mounting points). Keep fasteners organized by location.
   Torque spec

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

   Withdraw the headlight assembly
   Carefully pull the assembly straight forward and out. Watch for any remaining harness clips or alignment dowels at the rear of the housing. Do not let the housing rest on the stainless panels.
   ⚠If the assembly does not release with light pulling force, stop and recheck for a missed fastener — do not pry.
7. 7

   Transfer any reusable hardware to new assembly
   Compare the new assembly to the old one. Transfer any brackets, isolators, or alignment pins only if the new assembly does not include them. Verify the new unit matches the original part configuration.
8. 8

   Install new headlight assembly
   Position the new assembly into the vehicle, ensuring alignment dowels seat correctly. Hand-thread all mounting bolts before final torque to allow the assembly to self-align with the surrounding trim.
   Torque spec

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

   Torque headlight mounting bolts
   Torque all headlight mounting bolts in a cross/staged pattern to specification. Verify even gap between the headlight and surrounding fascia/exoskeleton before final torque.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
10. 10

    Reconnect electrical connector
    Reconnect the headlight harness connector and confirm the locking tab fully engages (audible click). Route the harness away from any moving or hot components. If the connector is secured by a small retaining screw, torque to specification.
    Torque spec

    Connector Screws4 Nm (3 lb-ft)
11. 11

    Adjust headlight aim if equipped with mechanical adjusters
    If the assembly has external mechanical aim adjusters, perform a preliminary aim against a level wall target per the manufacturer-specified procedure. Final aim calibration on Cybertruck is typically performed via the vehicle service software.
    ℹ️Final headlight aim/calibration on Cybertruck may require Tesla service software. Mechanical pre-aim is a starting point only.
    Torque spec

    Adjuster Screws3 Nm (2 lb-ft)

Reassembly

1. Reinstall the fascia/light bar trim, ensuring all clips fully seat.
2. Reinstall the wheel arch liner with all original push-pins and Torx fasteners; replace any broken retainers.
3. Reinstall the frunk trim/scuff panel.
4. Reconnect the 48V low-voltage battery; torque the battery terminal hardware to specification.
5. Close frunk, verify alignment of the headlight to surrounding panels with even gaps.

Verification

• Power on the vehicle and cycle low beams, high beams, DRL, turn signal, and any cornering/welcome light functions on the affected side.
• Confirm no headlight, lighting, or vehicle network fault appears on the center display.
• Verify automatic high-beam (if equipped) functions at night — failure indicates the camera/headlight calibration was disturbed.
• Perform headlight aim verification against a level target wall; if Cybertruck-specific calibration is required by service software, schedule that step or have it performed at a Tesla-certified facility.
• Inspect for water-tight seating of the headlight gasket after a drive in rain or a hose test — Cybertruck's off-road duty cycle exposes the front end to significant water intrusion.
• Re-torque check the mounting bolts after the first 100 miles if the vehicle is used off-road.

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