2026-09-16

Front Frame Rail (Rear Wheel Drive Vehicles Built Through April 10, 2016)

Correction code: 10101200102 10101200202 NOTE: Unless explicitly stated in the procedure, the above correction code includes all Collision Repair and Service repair work required to perform this procedure, including the linked Collision Repair procedures and linked Service procedures. Do not stack Collision Repair correction codes unless explicitly told to do so. Depending on the damage to the vehicle, additional repairs may be required.

Parts List

Quantity Description Image / Notes
1 ASY - FR RAIL SVC (Front Frame Rail)
3 Structural Flange Rivet
8 Structural Rivet, 6.5 mm Medium
4 Structural Rivet, 6.5 mm Short
3 Bolt, hex-head , BOLT HF M10X1.50X30 [10.9]-U-MP-G720 Tesla part number 2007069.

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 Wheel Arch Liner - Front - LH (Remove and Replace).
  2. Remove the Carrier - Bumper - Front (Remove and Replace).
  3. Remove the Fender Assembly - Front - LH (Remove and Install).
  4. LH Component only: Remove the AC LINE ASSM, DISCHARGE (see the Service Manual).
  5. LH Component only: Remove the Brake Lines - Primary 2-Tube Bundle (Remove and Replace) (see the Service Manual).
  6. LH Component only: Remove the MS RWD Brakes - Brake Pipes and Hoses - Brake Lines - ABS to Front Wheels and Junction Block (RR).
  7. RH Component only: Remove the Pipe - High Pressure - Charge Port (Remove and Replace).
  8. RH Component only: Remove the Pipe - Low Pressure - Charge Port (Remove and Replace).
  9. Remove the Air Spring Module - Front - LH (Remove and Replace).
  10. Remove the Harness - Adaptive Air Spring Module - Front - LH (Remove and Replace).
  11. Remove the Drive Unit - Front (2nd Generation) (Remove and Replace).
  12. Remove the original component.
    or Factory Structural Rivets
    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, hex-head

    Factory Pin and Collar

    Bolt, Allen-head
    Note
    This bolt is removed from the assembly, but does not leave the body of the vehicle. The bolt is reused during component installation.

    GMA Weld

  13. Prepare for installation.
    or Structural Flange Rivets, 6.5 mm

    or Structural Rivets, 6.5 mm Medium

    or Structural Rivets, 6.5 mm Short

    or Bolts, hex-head

    Bolt, Allen-head

    GMA Weld

  14. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  15. Install the new component or components.
    Torque all bolts to 50 Nm.
  16. Perform GMA welding.

    GMA Weld

    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
    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.
    CAUTION
    Do not weld on a Tesla vehicle before performing the Vehicle HV Disablement Procedure (refer to the vehicle-specific Service Manual for more information on the Vehicle HV Disablement Procedure). Welding on a Tesla vehicle with an energized high or low voltage system might damage vehicle components.
    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.
  17. Perform any necessary post-repair operations.
  18. Install the Drive Unit - Front (2nd Generation) (Remove and Replace).
  19. Install the Harness - Adaptive Air Spring Module - Front - LH (Remove and Replace).
  20. Install the Air Spring Module - Front - LH (Remove and Replace).
  21. RH Component only: Install the Pipe - Low Pressure - Charge Port (Remove and Replace).
  22. RH Component only: Install the Pipe - High Pressure - Charge Port (Remove and Replace).
  23. LH Component only: Install the MS RWD Brakes - Brake Pipes and Hoses - Brake Lines - ABS to Front Wheels and Junction Block (RR).
  24. LH Component only: Install the Brake Lines - Primary 2-Tube Bundle (Remove and Replace) (see the Service Manual).
  25. LH Component only: Install the AC LINE ASSM, DISCHARGE (see the Service Manual).
  26. Install the Fender Assembly - Front - LH (Remove and Install).
  27. Install the Carrier - Bumper - Front (Remove and Replace).
  28. Install the Wheel Arch Liner - Front - LH (Remove and Replace).