2025-08-06

Front Frame Rail (Complete)

Correction code: 10101012602 10101012702 NOTE: Unless explicitly stated in the procedure, the above correction code includes all Collision Repair work required to perform this procedure, including the linked Collision Repair procedures. Do not stack Collision Repair correction codes unless explicitly told to do so. Add any associated mechanical procedures needed to perform this procedure.

Parts List

Quantity Description Image / Notes
1 ASY - FRONT RAIL COMPLETE (Front Frame Rail – Complete)
1 LONGITUDINAL UPPER (Longitudinal Upper)
51 High Strength Structural Rivet, 6.5 mm
22 Structural Bulb Rivet, 6.5 mm
2 Countersunk Rivet, 4.8 mm Short
10 Countersunk Rivet, 4.8 mm Long
1 Rivet, 4.8 mm
1 Structural Countersunk Rivet, 6.5 mm
5 Bolt Tesla part number 1011818-00-A.
5 Nut Tesla part number 1006628-01-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

  1. Remove the Shotgun Outer.
  2. Remove the Dash Crossmember.
  3. Remove the Toeboard Outer Panel.
  4. Remove the original component.
    or Factory Spot Welds
    or Drill through factory spot welds
    Informational PurposesAn informational icon, calling your attention
    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.
  5. Prepare to install the Longitudinal Upper on the Front Rail Complete service part.
    or High Strength Structural Rivets, 6.5 mm

    or Countersunk Rivets, 4.8 mm Long

    or Rivets, 4.8 mm

  6. Apply structural adhesive to the mating surfaces of the Longitudinal Upper on the Front Rail Complete service part.
  7. Install the Longitudinal Upper on the Front Rail Complete service part.
  8. Prepare for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    A red X indicates a location where a factory-installed fastener is not being replaced.
    or High Strength Structural Rivets, 6.5 mm
    or Structural Bulb Rivets, 6.5 mm
    • A = 7 mm

    or Countersunk Rivets, 4.8 mm Short

    or Countersunk Rivets, 4.8 mm Long

    or Structural Countersunk Rivets, 6.5 mm

    or Bolts

    Nut

  9. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  10. Install the new component or components.
    Torque the bolts to 22 Nm.
  11. Install the Shotgun Outer.
  12. Install the fasteners as indicated.
    or High Strength Structural Rivets, 6.5 mm
  13. Install the Dash Crossmember.
  14. Install the Toeboard Outer.
  15. Install the Fender and Lamp Support Bracket Assembly.
  16. Install the fastener as indicated.
    or High Strength Structural Rivets, 6.5 mm
  17. Perform any necessary post-repair operations.