Front Header Connectors (Vehicles Built Through October 2, 2016)
Repair Information
The Model S Front Header Assembly may be connected to the vehicle with either 1st Generation or 2nd Generation Header Connector Brackets. Examine the Header Connector Brackets on the vehicle being repaired and select the appropriate procedure to use for the repair:
|
Vehicles Built Through October 2, 2016 (1st Generation Header Connector Brackets)
|
Vehicles Built On or After October 3, 2016 (2nd Generation Header Connector Brackets)
|
|
If the vehicle being repaired has this type of Front Header Connector, proceed with the this procedure. |
If the vehicle being repaired has this type of Front Header Connector, do not continue this procedure; instead, proceed with the Front Header Connectors (Vehicles Built After October 2, 2016) procedure. |
- 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, REINF - FR HEADER CONNECTOR (Front Header Connector) |
|
| 4 |
High Strength Structural Rivet, 6.5 mm
|
|
| 5 |
Structural Rivet, 6.5 mm Medium
|
|
| 8 |
Flow Form Rivet S58
|
|
| 2 |
Bolt, hex-head
,
BLT,HFLG,M10x22[10.9]-MM-11 |
Tesla part number 1012961-00-A. |
| 2 |
Nut
,
HEX,M8,1.25,STL,ZN,PATCH, W/WSHR |
Tesla part number 1004400-00-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 component that
covers the header assembly:
Depending on the vehicle build date, the component that covers the header assembly may be any of the following:
- Roof Assembly (refer to procedure)
- Roof Glass (refer to procedure)
- Panoramic Roof Assembly frame (refer to procedure)
-
Remove the original component.
or 
Factory Spot Welds
NoteThe highlighted spot weld may not be apparent on all vehicles.
GMA Weld
-
Prepare for installation.
or High Strength Structural Rivets, 6.5 mm
- A = 7 mm.
- B = 27 mm.
- C = 10 mm.
- D = 25 mm.
- E = 8 mm.
- F = 127 mm.
- G = 145 mm.
or Flow Form Rivets, S58
- E = 8 mm.
- F = 127 mm.
- G = 145 mm.
or Structural Rivets, 6.5 mm Medium
- H = 12 mm.
- I = 15 mm.
- 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 25 Nm.
-
Install the component that
was removed to provide access to the header assembly:
- Roof Assembly (refer to procedure)
- Roof Glass (refer to procedure)
- Panoramic Roof Assembly frame (refer to procedure)
- Perform any necessary post-repair operations.
