03/07/2024 16:03:53

Sill (Outer Section)

Repair Information

  • This repair procedure can be used to repair damage to any area of the Side Sill Outer up to 374 mm. in length. If the damaged area is more than 374 mm in length, the Side Sill Outer cannot be repaired: replace the Side Sill using the Sill (Complete) procedure.
  • Depending on the damage to this component, it may be possible to repair this component. Refer to Sill Repair Guidelines for more information.

  • 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.

Parts List

Quantity Description Image / Notes
1 ASY SIDE SILL (Sill Assembly)
1 MIDDLE CELL BACKING PLATE - 510 MM (Middle Cell Backing Plate)
1 LOWER CELL BACKING PLATE (Lower Cell Backing Plate)
13 High Strength Structural Rivet, 6.5 mm
58 Structural Countersunk Rivet, 6.5 mm
17 Structural Rivet, 6.5 mm Medium
7 Rivnut, M6 - 1.00x3 Tesla part number 2007016.
2 Rivnut, M8 - 1.25x16 Tesla part number 1014282-00-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

  1. Remove the necessary portion of the Body Side Outer to expose the underlying component being replaced.
  2. Remove the Sill Insert.

    or Factory Structural Rivets

    Rivnut

  3. Remove the damaged area of the original component.

    Cut Line

    Reference Line/Point

    • A = Up to 374 mm.
    • B = 57 mm.
    • C = 90 mm.
  4. Cut the new ASY SIDE SILL to fit the repair area to make the new component.

    Cut Line

    Reference Line/Point

    • D = Up to 374 mm. (trim to fit the repair area)
    • E = 57 mm.
    • F = 90 mm.
  5. Cut the new MIDDLE CELL BACKING PLATE and the LOWER CELL BACKING PLATE to a length 80 mm. longer than the repair area to create backing plates for the repair area.
  6. Install the backing plates in the repair area.

    or High Strength Structural Rivets, 6.5 mm

    or Structural Countersunk Rivets, 6.5 mm

    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    When installing the backing plates, allow adequate space to install the Sill Insert.
    Informational PurposesAn informational icon, calling your attention
    Note
    Depending on the location of the repair area, rivnuts for a jack pad may have to be removed to insert and install the lower backing plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    If rivnuts for a jack pad were removed to insert and install the lower backing plate, install new rivnuts in those locations once the backing plates are installed.
  7. Install the Sill Insert.
    or Structural Rivets, 6.5 mm Medium
    Informational PurposesAn informational icon, calling your attention
    Note
    Backing plates must be installed before positioning the Sill Insert for installation.
  8. Prepare for installation.
    or High Strength Structural Rivets, 6.5 mm

    or Structural Countersunk Rivets, 6.5 mm

    GMA Weld

  9. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  10. Install the new component or components.
  11. Perform GMA welding.
    GMA Weld
    Informational PurposesAn informational icon, calling your attention
    Note
    Grind the welds down until they are flush with the panel.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    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 IconA warning icon, calling your attention to a possibly risky situation
    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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
  12. Install the fasteners as indicated.
    Rivnut
  13. Install the portion of the Body Side Outer that was removed to expose the component being replaced.
  14. Perform any necessary post-repair operations.