Chargeport Micro Switch problem

This happened in Steve Hand's car, too. His was repaired by Tesla (living close to Menlo Park is a definite advantage).

Our charge port door micro switch got some water inside it which caused all sorts of problems with the car. Rangers came to fix it and I think it took at least a couple hours for one of them to remove the assembly from the car so that it could be repaired. They did have to remove the panel behind the rear window but I didn't see the details.

I recently had the same issue as the OP with the charge port switch not connecting anymore and decided to fix it myself. In order to get to the switch, I followed the procedure in the service manual called "Light Ring Assembly - Charge Port". It is rather involved, but mostly straightforward. The trickiest parts of the procedure are:
1) Hard-to-reach screws and nuts. I was only able to access one of the nuts securing the hinge bracket with my torque wrench and had to tighten the other by hand when reassembling. 2) Getting the trunk lid aligned again. The service manual says that fitted position of trunk hinges to trunk lid should be marked before disassembly. However, there is also quite some margin for placement of the hinge on its bracket, so I think that should be marked also. In my case the trunk lid couldn't be closed on first try after I had put everything together. I took the panel behind the rear window off again and adjusted the hinge mounting. In retrospect, it is probably wise to put this panel back last.

Once the light ring assembly is off, the door switch assembly (with the door) can be removed. It is secured by two nuts (8mm). I could not find anything to adjust on the assembly so I gave that up. It turned out that the switch worked, but appeared to be actuated just outside the threshold for toggling when mounted in the car. An indication is that I could toggle it by pushing on the lid. Assuming the switch was somehow worn, I replaced it. Unfortunately the problem remained. I therefore ended up simply bending the lever of the switch. That worked.

P.S.: The door switch assembly (Tesla part no. 6000036) is no longer available according to Tesla. The microswitch itself is an Omron device. I used Omron part no. D2HWC233MRBYOMR as a replacement. Visually and electromechanically the original and the replacement are indistinguishable to me. They may be the same, except that the switch I bought needs to have a connector mounted to the leads. I think TE Connectivity Mini Multilock, part no. 917319 or 2822344 for the housing and 917309 for the tab contact would be the right choices. These appear sold out everywhere, so I bought these Harley Throttle By Wire Amp/Tyco 7 wire Green Mini Multi-lock Female Connector | eBay which are probably the same.