03/07/2024 16:01:27

Door Ring Outer

Repair Information

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	ASY - DOOR RING OUTER (Door Ring Outer)
1	SIDE SILL INSERT
2	BRACKET - SILL INSERT MOUN
4	High Strength Structural Rivet, 6.5 mm
3	Countersunk Rivet, 4.8 mm Short
14	Rivet, 4.8 mm
4	Flow Form Rivet S28
4	Bolt , BOLT HH M8X29 109 G1009 B M	Tesla part number 1623708-00-A.

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 necessary portion of the Body Side Outer Assembly to expose the underlying component being replaced.
Remove the Shotgun Outer
Remove the C–Pillar Reinforcement.
Remove the Roof Rail Extension.
Remove the original component.

or Factory Spot Welds

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.

or Bolts
Remove the Sill Insert.
Mark the center lines for the Sill Insert Mounting Brackets on the new Sill Insert as shown below.
Note
The measurements are from the end of the Sill Insert to the center of the Sill Insert Mounting Bracket.
- A = 399 mm.
- B = 420 mm.
Mark the new Sill Outer to show the location for the new Sill Insert.
- C = 177 mm.
Using the bracket center lines drawn earlier, position the Sill Insert Mounting Brackets between the Sill Insert and the Door Ring outer, then adjust the brackets so that they make contact with the Door Ring Outer.
Prepare to install the mounting brackets on the new Sill Insert.
or High Strength Structural Rivets, 6.5 mm
Apply structural adhesive to the mating surfaces on the new Sill Insert and the new Sill Insert Mounting Brackets.
Install the new Sill Insert Mounting Brackets on the new Sill Insert.
Prepare to install the new Sill Insert in the new Sill Outer.

or Rivets, 4.8 mm
Apply structural adhesive to the mating surfaces on the new Sill Insert, the new Sill Insert Mounting Brackets, and the Door Ring Outer.
Install the new Sill Insert on the new Sill Outer portion of the Door Ring Outer assembly.
Prepare to install the new Door Ring Outer.
Note
A red X indicates a location where a factory-installed fastener is not being replaced.

or Installation Spot Welds

or High Strength Structural Rivets, 6.5 mm

or Countersunk Rivets, 4.8 mm Short
or Rivets, 4.8 mm
- D = 9 mm.
- E = 96 mm.
or Flow Form Rivets, S28

or Bolts
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
Install the new component or components.
Torque the bolts to 19 Nm.
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.
Install the Roof Rail Extension.
Install the C–Pillar Reinforcement.
Install the necessary portion of the Body Side Outer Assembly that was removed to expose the component being replaced.
Install the Shotgun Outer
Perform any necessary post-repair operations.