03/07/2024 16:03:49

Shotgun Upper Assembly

Using this Document

This document contains two major parts:
  1. Shotgun Upper Section Descriptions provides information on where and how to section the Shotgun Upper Assembly as necessary to replace damaged areas of the Shotgun Upper panel, or to gain access to underlying parts of the vehicle structure. Use the section descriptions to determine where to successfully section the Shotgun Upper Assembly as needed for the repair being performed.
    Informational PurposesAn informational icon, calling your attention
    Note
    Sections of the Shotgun Upper Assembly can be replaced individually or in any combination of sections so long as the referenced cut locations identified in this document are used.
    Informational PurposesAn informational icon, calling your attention
    Note
    Measurements from bolt hole locations are from the center of the referenced holes unless stated differently in the section description.
  2. The Removal and Replacement portions of this document contain the information necessary to replace the entire Shotgun Upper Assembly. If replacing a section of the Shotgun Upper Assembly (not the entire Shotgun Upper), use the relevant portions of each step to determine which parts and fasteners are needed and the necessary steps to complete the repair.

Parts List

Quantity Description Image / Notes
1 SHOTGUN UPPER (Shotgun Upper Assembly)
4 Structural Rivet, 6.5 mm Medium
10 SPR, 5x4.5
3 SPR, 5x6 H4
3 SPR, 5x6.5
1 Bolt, hex-head , BOLT,HF,M6-1.0x21[88],G1009[B],MAT Tesla part number 1139785-00-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.

Shotgun Upper Section Descriptions

Shotgun Upper Service Assembly and Sections
The Shotgun Upper Complete is a single component, and can be replaced as a single repair. Alternatively, instead of replacing the complete Shotgun Upper, areas of the Shotgun Upper can be replaced using sections of the Shotgun Upper Assembly using the cut lines described in this document.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
When cutting sections, do not cut bolt holes.
Informational PurposesAn informational icon, calling your attention
Note
Install a backing plate behind each butt joint if there is sufficient space and use structural adhesive to fill any gaps behind panels and underlying components.
Assembly Sections

Shotgun Upper Section

Front Section

Informational PurposesAn informational icon, calling your attention
Note
Order an additional SHOTGUN UPPER when performing this repair.

Cut Line

Reference Line/Point

  • A = 40 mm.

Create and install a backing plate as indicated.

GMA Weld

or Aluminum Plug Welds

Rear Section

Informational PurposesAn informational icon, calling your attention
Note
Order an additional SHOTGUN UPPER when performing this repair.

Cut Line

Reference Line/Point

  • B = 124 mm.

Create and install a backing plate as indicated.

GMA Weld

or Aluminum Plug Welds

Repair Procedure

  1. Remove the original component.

    or Factory Spot Welds

    or Factory Structural Rivets

    or Bolts, hex-head

    Informational PurposesAn informational icon, calling your attention
    Note
    Some vehicles have a GMA weld that attaches the Shotgun Upper to the Shock Tower. If present, remove the weld.

    GMA Weld

  2. Position the new component, measure as shown, and clamp the new component in place.
  3. Prepare for installation.

    or Structural Rivets, 6.5 mm Medium

    or SPRs, 5x4.5
    Informational PurposesAn informational icon, calling your attention
    Note
    For the SPRs not circled in red, use the following Tesla SPR die to install this SPR: KA 075 2113.
    • A = 10 mm.
    • B = 45 mm.
    • C = 36 mm.
    • D = 78 mm.
    Informational PurposesAn informational icon, calling your attention
    Note
    For the SPRs circled in red, use the following Tesla SPR die to install the SPRs: SM 110 0108.
    or SPRs, 5x6 H4
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the following Tesla SPR die to install this SPR: SM 110 0108.
    or SPRs, 5x6.5
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the following Tesla SPR die to install this SPR: SM 085 0125.

    or Bolts, hex-head

  4. If the original assembly was attached to the Front Shock Tower with a GMA weld: Prepare for installation.

    GMA Weld

  5. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  6. Install the new component or components.
    Torque the bolt to 10 Nm.
  7. If performing a section repair only: Perform GMA welding on the butt joints.

    or Aluminum Plug Welds

    GMA Weld

    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.
  8. If the original assembly was attached to the Front Shock Tower with a GMA weld: GMA weld the Shotgun Upper Assembly to the Front Shock Tower.

    GMA Weld

    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.
  9. Perform any necessary post-repair operations.