03/07/2024 16:02:43

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

Repair Information

Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.
Properly mount the vehicle on a frame bench when performing 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

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.

Remove the Shotgun Upper Assembly.
Remove the Shotgun Outer Assembly.
Remove the necessary portion of the Body Side Outer to expose the underlying component being replaced.
If the vehicle was equipped with a bow header: Detach the Bow Header.
or Factory Spot Welds
or Bolts, hex-head
Remove Hinge Pillar Assembly.
Remove the original component.
or Factory Spot Welds

or Factory SPRs

Cut Line

Reference Line/Point
- A = 160 mm.
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
Cut the new ASSY - A / B PILLAR COMP as indicated below to make the new component.
Cut Line

Reference Line/Point
- B = 163 mm.
Create and install the backing plate.
or Aluminum Plug Welds
Install B–Pillar Gusset Ramp
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
Note
Use the following Tesla SPR die to install this SPR: FM 090 2120.

or SPRs, 5x8
Note
Use the following Tesla SPR die to install this SPR: FM 090 2120.

or SPRs, 5x9
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
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
Install the new component or components.
Torque the nuts and bolts to 25 Nm.
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 portion of the Body Side Outer that was removed to expose the component being replaced.
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.
Install the Shotgun Outer Assembly.
Install the Shotgun Upper Assembly.
Perform any necessary post-repair operations.