03/07/2024 16:00:04

Quarter Outer Assembly (Without Upper Trough)

Repair Information

Note

If the repair area includes any portion of the Roof Rail, do not use this procedure; instead, refer to the Body Side Outer Assembly.

Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.
This procedure can be completed without using a frame bench.
Any individual section or any combination of sections of the Body Side Outer Assembly can be replaced so long as the referenced cut lines from the Quarter Outer Assembly Section Descriptions portion of this document are used.

Using this Document

This document contains two major parts:

Quarter Outer Assembly Section Descriptions provides information on where and how to section the Quarter Outer Assembly (or subassemblies) as necessary to replace damaged areas of the Quarter Outer assembly, or to gain access to underlying parts of the vehicle structure. Use the section descriptions to determine where to successfully section the Body Side Outer Assembly as needed for the repair being performed.
Note
Sections of the Quarter Outer Assembly can be replaced individually or in any combination of sections so long as the referenced cut locations identified in this document are used.
Note
Measurements from bolt hole locations are from the center of the referenced holes unless stated differently in the section description.
The Repair Procedure portion of this document contain the information necessary to replace the entire Quarter Outer Assembly. If replacing sections of the Quarter Outer (not the entire Quarter Outer Assembly), use the relevant portions of each step to determine which parts and fasteners are needed and the steps required to complete the repair.

Parts List


Quantity	Description	Image / Notes
1	ASSEMBLY, REAR QUARTER OUTER (Rear Quarter Outer Assembly)
10	Structural Bulb Rivet, 6.5 mm
12 LH or 11 RH	Flow Form Rivet S18

When ordering parts, refer to the Parts Catalog and enter the VIN of the vehicle being repaired to find the correct parts (and the part numbers) for the vehicle. Alternatively, use the search function in the Parts Catalog to find a specific part for the vehicle.

Quarter Outer Assembly Section Descriptions


Quarter Outer Assembly Sectioning
The Quarter Outer Assembly is a single assembly, and can be replaced as a single repair, or instead of replacing the complete Quarter Outer Assembly, areas of the Quarter Outer can be replaced using portions of the complete Quarter Outer Assembly using the cut lines described in this document.


Quarter Outer Section Descriptions	Joint Descriptions
Quarter Outer Skin Section Cut Line Warning Do not cut the Body Side Outer panel directly over the underlying Rear Wheelhouse Reinforcement panel. Reference Line/Point A = 75 mm. B = 5 mm. Note Measure from the side of the hole as indicated in the image. GMA Weld Note The gap between the adjacent panels of the butt joint for this section should be as small as possible to maximize joint strength. Note Fill gaps in welded seams using structural adhesive and seal any open seams after welding.
Dogleg Section Cut Line Reference Line/Point C = 110 mm. Note Measure from the side of the hole as indicated in the image. Warning Do not cut the steel Body Side Outer panel directly over the underlying aluminum components. The underlying components (highlighted in red) include both the Rear Wheelhouse Reinforcement and the Rear Wheel Arch Assembly. GMA Weld Note The gap between the adjacent panels of the butt joint for this section should be as small as possible to maximize joint strength. Note Seal all open seams after welding.
Rear Sill Section Cut Line Reference Line/Point D = 350 mm. GMA Weld Note The cut can be made within 50 mm. to either side of the specified cut line. Note The gap between the adjacent panels of the butt joint for this section should be as small as possible to maximize joint strength. Note Seal all open seams after welding.
Rear Roof Rail Section Note If the repair area includes any portion of the Roof Rail, do not use this procedure; instead, refer to the Body Side Outer Assembly.

Repair Procedure

Remove the Upper Trough from the Rear Quarter Outer Assembly service part.
or Factory Spot Welds
or Drill through factory spot welds
Note
When drilling out spot welds, use a drill bit that creates a hole correctly sized for the fastener that will replace the spot weld.
Remove the original component.
or Factory Spot Welds
Note
Do not remove spot welds in the areas highlighted with yellow circles.

or Factory SPRs

or Drill through factory spot welds
Note
When drilling out spot welds, use a drill bit that creates a hole correctly sized for the fastener that will replace the spot weld.
Separate the Wheel Arch flange.
Prepare for installation.

Note
A red X indicates a location where a factory-installed fastener is not being replaced.

or Installation Spot Welds

or Steel Plug Welds

GMA Weld

or Structural Bulb Rivets, 6.5 mm

or Flow Form Rivets, S18
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
Install the new component or components.

Note
The Body Side Outer lower flange is secured using structural adhesive only.
Fold over the wheel arch flange.
Perform resistance spot welding.
or Installation Spot Welds
Warning
Failure to follow all welding safety precautions, including the use of personal protective equipment, could result in serious injury or property damage. Only technicians who have completed Tesla’s approved welding training are authorized to weld structural components on Tesla vehicles.

CAUTION
Do not weld on a Tesla vehicle before performing the Vehicle Electrical Isolation Procedure (refer to the vehicle-specific Service Manual for more information on the Vehicle Electrical Isolation Procedure). Welding on a Tesla vehicle with an energized high or low voltage system might damage vehicle components.
Perform GMA welding.
or Steel Plug Welds
GMA Weld

Warning
Failure to follow all welding safety precautions, including the use of personal protective equipment, could result in serious injury or property damage. Only technicians who have completed Tesla’s approved welding training are authorized to weld structural components on Tesla vehicles.

Warning
To maintain vehicle crash integrity, use only approved welding wire and an approved GMA welder to perform GMA welding on Tesla vehicles. Refer to Approved Gas Metal Arc (GMA) Welders and Welding Wire for information on approved GMA welders and welding wire.

CAUTION
Do not weld on a Tesla vehicle before performing the Vehicle Electrical Isolation Procedure (refer to the vehicle-specific Service Manual for more information on the Vehicle Electrical Isolation Procedure). Welding on a Tesla vehicle with an energized high or low voltage system might damage vehicle components.

Note
Before GMA welding, a test weld using material of the same gauge and type should be performed to make sure that the welding equipment settings produce a satisfactory joint.
Fill the indicated seam with structural adhesive.
For the plug weld circled in red, seal the hole left from drilling the backside of the plug weld.
Fold over the Wheel Arch flange.
If the original Charge Port Housing had a ground wire or harness attachment point, drill a hole in the new Charge Port Housing for a Rivnut or a retainer clip. (Refer to the Charge Port Housing Assembly procedure for information about the size and location of the hole.)
Perform any necessary post-repair operations.