Tonneau cover leak DIY fix (cause: seal strip gap under aero flap)

wheeler · Apr 24, 2024

I noticed that most leaking in my CT bed during rain and carwash happened in one spot under the aero flap.

Tesla Cybertruck Tonneau cover leak DIY fix (cause: seal strip gap under aero flap) 20240423231344

Tesla Cybertruck Tonneau cover leak DIY fix (cause: seal strip gap under aero flap) 20240423231412

So I took the aero flap off, found out that the seal strip under it has a gap right at the leaking spot.

Tesla Cybertruck Tonneau cover leak DIY fix (cause: seal strip gap under aero flap) 20240423233502

Tesla Cybertruck Tonneau cover leak DIY fix (cause: seal strip gap under aero flap) 20240423231423

Comparing the left and right mounting locations of the aero flap, I also noticed the seal strip is very off at the left end, almost missing. (Marked green in photo.) And the roof glass is not well aligned

.(Red marks.)

Tesla Cybertruck Tonneau cover leak DIY fix (cause: seal strip gap under aero flap) Untitled-1

I filled the gap, put the aero flap back, then the leaking is gone, at least for now.

@Technigogo posted a video showing detailed instruction to take off and put on the aero flap, in case anyone needs to watch it.

BChiesa · Apr 24, 2024

Good to know. Thanks!

Treynor · Apr 24, 2024

THIS is valuable info!
thanks for helping all of us increase the quality of our CT!
good post.

joeliroquai · Apr 24, 2024

What did you use to fill the gaps?

JBerger · Apr 24, 2024

well done

wheeler · Apr 24, 2024

joeliroquai said:
What did you use to fill the gaps?

E6000 and random elastic foam. Not sure how long they can last though.

The Tesla Guy · Apr 24, 2024

Maybe this is a silly question.
Why not take it to a service center?
I think it helps make the engineers aware of a problem in the field, allowing more permanent solutions in both the manufacturing and after delivery repairs.

Cyber Man · Apr 24, 2024

Great info! Thanks for sharing. I saw some video footage of Tesla engineers taking CT to car wash and the engineer getting inside the truck bed with Vault closed. I’m sure he was there to test the leak. No idea how they missed this gap. Hope they fix it soon.

futureproof · Apr 24, 2024

I guess $100K doesnt buy what it used to.

kosmo886 · Jun 23, 2024

wheeler said:
I noticed that most leaking in my CT bed during rain and carwash happened in one spot under the aero flap.

So I took the aero flap off, found out that the seal strip under it has a gap right at the leaking spot.

Comparing the left and right mounting locations of the aero flap, I also noticed the seal strip is very off at the left end, almost missing. (Marked green in photo.) And the roof glass is not well aligned .(Red marks.)

I filled the gap, put the aero flap back, then the leaking is gone, at least for now.

@Technigogo posted a video showing detailed instruction to take off and put on the aero flap, in case anyone needs to watch it.

I have the same issue. Why not simply silicone it to avoid needing to disassemble? My gap is right at the water drop in the photo. Was going to just put some silicone caulking over that portion of the strip. I'd think it should do the trick.

Tesla Cybertruck Tonneau cover leak DIY fix (cause: seal strip gap under aero flap) gasket

EricM · Jul 13, 2024

They might’ve changed the design on newer build trucks because mine doesn’t look like that at all (or they left the foam out of mine). Mine sure leaks like there’s nothing there.

Tesla Cybertruck Tonneau cover leak DIY fix (cause: seal strip gap under aero flap) IMG_0978

Tesla Cybertruck Tonneau cover leak DIY fix (cause: seal strip gap under aero flap) IMG_0977

Sirkevin · Jul 14, 2024

Is the gap at the end of the roll normal ? water get though.

Tesla Cybertruck Tonneau cover leak DIY fix (cause: seal strip gap under aero flap) IMG_9753

wheeler · Jul 14, 2024

Sirkevin said:
Is the gap at the end of the roll normal ? water get though.

Not normal. Mine is like this:

Tesla Cybertruck Tonneau cover leak DIY fix (cause: seal strip gap under aero flap) 20240714132552

wheeler · Jul 14, 2024

EricM said:
They might’ve changed the design on newer build trucks because mine doesn’t look like that at all (or they left the foam out of mine). Mine sure leaks like there’s nothing there.

It looks to me that there is a dislocation of the whole seal strip towards the front of the vehicle. Same as the left end of mine(Marked with green lines).

wheeler said:

Sirkevin · Jul 14, 2024

thanks i got a repair schedule for it when i picked it up because it was leaking already.

Tonneau cover leak DIY fix (cause: seal strip gap under aero flap)

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