2026-08-10

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

Correction code: 10101004502 10101004702 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.

Repair 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 - FR RAIL OTR EXTN (Front Frame Rail Outer Extension)
3	Structural Flange Rivet
23	Structural Rivet, 6.5 mm Medium
11	Structural Rivet, 6.5 mm Short

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 Air Spring Module - Front - LH (Remove and Replace).
Remove the Link - Aft - Lower - LH (Remove and Replace).
Remove the Knuckle - Suspension - Front - LH (Remove and Replace).
Remove the Link - Fore - Lower - Front - LH (Remove and Replace).
Remove the Front Frame Rail Outer Extension Reinforcement.
Remove the original component.

or Factory Spot Welds

or Factory SPRs

or Factory Structural Rivets

Factory Pin and Collar

GMA Weld
Prepare for installation.
or Structural Flange Rivets, 6.5 mm
or Structural Rivets, 6.5 mm Medium

or Structural Rivets, 6.5 mm Short

GMA Weld
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
Install the new component or components.
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 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.

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.
Install the Front Frame Rail Outer Extension Reinforcement.
Perform any necessary post-repair operations.
Install the Link - Fore - Lower - Front - LH (Remove and Replace).
Install the Knuckle - Suspension - Front - LH (Remove and Replace).
Install the Link - Aft - Lower - LH (Remove and Replace).
Install the Air Spring Module - Front - LH (Remove and Replace).