03/07/2024 16:00:14

Rear Frame Rail

Repair Information

The Rear Rail Upper Assembly and Rear Rail Lower Assembly might come with studs installed. If these components come with studs installed, remove the studs at the appropriate step in this procedure.
Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.
Properly mount the vehicle on a frame bench when performing this procedure.

Parts List


Quantity	Description	Image / Notes
1	Rear Rail Upper Assembly
1	Rear Rail Lower Reinforcement
1	Rear Rail Lower Assembly
1	Rear Rail Lower Glove	This component fits both left-hand and right-hand rails.
1	Brkt-Rr Rail to Bumper Plate (Rear Frame Rail End Plate)
42	High Strength Structural Rivet, 6.5 mm
1	Structural Bulb Rivet, 6.5 mm
12	Structural Rivet, 6.5 mm Medium
8	Bolt , M6 1.0x12	Tesla part number 1008770-00-A.
8	Nut , M6 1.0x14	Tesla part number 1016227-00-A.
2	Bolt, hex-head, M8 1.25x23.5	Tesla part number 1063260-00-C.

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.

Repair Procedure

Remove the Rear Body Panel.
Remove the Rear Rail to Lower Quarter Extension.
Remove the Trunk Floor Assembly (Complete).
Cut the original component at the indicated locations.

Cut Line
Remove the original component.

or Bolts
Note
Remove and discard the bolts.

or Factory SPRs
Note
The Frame Rail Inner Reinforcement (highlighted in red) must be removed to allow access to other factory SPRs.

Note
The factory SPRs circled in red are hidden behind the crossmember and must be ground down from inside the Frame Rail using a belt sander. When grinding the SPRs, do not knock out the SPRs entirely from the joint in order to keep some mechanical connection to the inboard bulkhead. These rivets are not replaced when installing the new Rear Rail Upper.

or Factory Spot Welds
Remove the remaining section of the Rear Rail Lower Assembly that protrudes from the Rear Node.

Note
Keep the remaining piece of the Rear Rail Lower Assembly to use as a template in a later step.
Prepare for installation.
Note
Use the remaining portion of the original Rear Rail Lower Reinforcement (removed in an earlier step) as a template to mark holes for bolts in the new component.

Note
A red X indicates a location where a factory-installed fastener is not being replaced.
or High Strength Structural Rivets, 6.5 mm
- A = 40 mm.
- B = 26 mm.
- C = 64 mm.
- D = 147 mm.
- E = 46 mm.
- H = 38 mm.
- I = 10 mm.
- J = 36 mm.
- K = 31 mm.
or Structural Bulb Rivets, 6.5 mm
- F = 12 mm.
- G = 10 mm.
or Structural Rivets, 6.5 mm Medium

or Bolts

Nut
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
Install the new component or components.

Note
Put the new Rear Rail Lower Reinforcement into position and install the new bolts (Tesla part number 1008770-00-A) and nuts (Tesla part number 1016227-00-A), and torque them to 13 Nm.

Note
When installing the Rear Rail Upper Assembly and the Rear Rail Lower Assembly, structural bulb rivets are installed in the flanges of both assemblies to secure them together. Install the structural bulb rivets in an alternating pattern: 1 from the Rear Rail Upper Assembly downward and then 1 from the Rear Rail Lower Assembly upward.

Note
Temporarily install the new bolts and nuts in the holes not being used for frame bench fixture bolts, but do not torque them fully at this time.

Torque the hex-head bolts, Tesla part number 1063260-00-C, to 24 Nm.
Install the Trunk Floor Assembly (Complete).
Install the new Rear Rail to Lower Quarter Extension.
Install the new Rear Body Panel.
Perform any necessary post-repair operations.