2025-08-06

A–Pillar and B–Pillar Complete Assembly (Vehicles Built Through October 11, 2016)

Correction code: 10100103802 10100107002 NOTE: Unless explicitly stated in the procedure, the above correction code includes all Collision Repair work required to perform this procedure, including the linked Collision Repair procedures. Do not stack Collision Repair correction codes unless explicitly told to do so. Add any associated mechanical procedures needed to perform this procedure.

Parts List

Quantity Description Image / Notes
1 ASSY - A / B PILLAR COMP (A–Pillar and B–Pillar Complete Assembly)
10 Structural Rivet, 6.5 mm Medium
8 Flow Form Rivet S58
2 Flow Form Rivet S68
5 SPR, 5x6 H4
2 SPR, 5x8
2 SPR, 5x9
4 Nut , NUT HF M8 PC10 Tesla part number 1046842-00-A.
2 Nut , NUT, HEX, M8, 1.25, STL, ZN,PATCH, W/ WSHR Tesla part number 1004400-00-A.
2 Bolt, hex-head , M8-1.25x20 Tesla part number 1012961-00-A.
If the vehicle was equipped with a bow header: 4 Bolt, hex-head Tesla part number 1004537-00-A.
If the vehicle was equipped with a bow header: 4 Flow Form Rivet S38

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

Informational PurposesAn informational icon, calling your attention
Note
Vehicles built through October 11, 2016 originally came with a 1st generation B-Pillar and Front Header. Component will be replaced with 2nd generation B-Pillar and Front Header.
  1. Remove the Shotgun Upper Assembly.
  2. Remove the Shotgun Outer Assembly.
  3. Remove the necessary portion of the Body Side Outer to expose the underlying component being replaced.
  4. If the vehicle was equipped with a bow header: Detach the Bow Header.
    or Factory Spot Welds

    or Bolts, hex-head

  5. Remove Hinge Pillar Assembly.
  6. Remove the original component.

    or Factory Spot Welds

    or Factory SPRs

    Cut Line

    Reference Line/Point

    • A = 160 mm.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    When removing the necessary portion of the Roof Rail Outer to expose the underlying joints, do not damage the Roof Rail Inner when cutting the Roof Rail Outer.

    GMA Weld

  7. Cut the new ASSY - A / B PILLAR COMP as indicated below to make the new component.

    Cut Line

    Reference Line/Point

    • B = 163 mm.
  8. Create and install the backing plate.
    or Aluminum Plug Welds
  9. Install B–Pillar Gusset Ramp
  10. Prepare for installation.
    or Structural Rivets, 6.5 mm Medium
    • C = 34 mm.
    • D = 30 mm.
    • E = 8 mm.
    • F = 127 mm.
    • G = 145 mm.

    or Flow Form Rivets, S58

    or Flow Form Rivets, S68

    or SPRs, 5x6 H4
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the following Tesla SPR die to install this SPR: FM 090 2120.
    or SPRs, 5x8
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the following Tesla SPR die to install this SPR: FM 090 2120.
    or SPRs, 5x9
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the following Tesla SPR die to install this SPR: FM 090 2120.

    or Bolts, hex-head

    Nut

    or Aluminum Plug Welds

    GMA Weld

  11. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  12. Install the new component or components.
    Torque the nuts and bolts to 25 Nm.
  13. Perform GMA welding.
    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.
  14. Install the portion of the Body Side Outer that was removed to expose the component being replaced.
  15. If the vehicle was equipped with a bow header: Attach the Bow Header.
    or Flow Form Rivets, S38 Bolt, hex-head

    Torque the bolts to 10 Nm.

  16. Install the Shotgun Outer Assembly.
  17. Install the Shotgun Upper Assembly.
  18. Perform any necessary post-repair operations.