03/07/2024 16:03:54

Sill (Rear Section)

Repair Information

  • If the damaged area of the Side Sill is not within 70 mm. of the rear edge of the Side Sill (measured from the bottom of the Side Sill), discontinue this procedure and perform the Sill (Complete) procedure.
  • Depending on the damage to this component, it may be possible to repair this component. Refer to Sill Repair Guidelines for more 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 SIDE SILL (Sill – Complete)
1 Upper Cell Lower Backing Plate

Tesla part number 1074848-00-A.
1 Upper Cell Upper Backing Plate

Tesla part number 1074920-00-A.
1 Middle Cell Backing Plate

Tesla part number 1074924-00-A.
1 Lower Cell Backing Plate

Tesla part number 1074922-00-A.
16 Structural Countersunk Rivet, 6.5 mm
19 High Strength Structural Rivet, 6.5 mm
3 Pop Rivets
1 Rivnut, NUT RVT RND THN M8-1.25X3.0 ZNNI Tesla part number 2007223.
3 Bolt, hex-head , BOLT PF M8X20 PC 98 ADH MAT Tesla part number 1014747-00-B.
2 Bolt, hex-head , BOLT HF M8X50 PC109 MAT Tesla part number 1046838-00-A.
2 SPAC NUT ,M8x3.8-5,STL[10],ZNI Tesla part number 1060097-00-B.

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 Rear Node Upper Reinforcement (Front).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the Rear Node Upper Reinforcement (Middle) or the Rear Node Upper Reinforcement (Rear).
  2. Remove the C–Pillar Reinforcement.
  3. Remove the Wheelhouse Extension.
  4. Remove the Sill Nut Strip.
    or Factory Structural Rivets
  5. Remove the original component.

    Cut Line

    Reference Line/Point

    • A = 80 mm.
    • B = 70 mm.

    or Bolts, hex-head

    GMA Weld
    Informational PurposesAn informational icon, calling your attention
    Note
    An additional weld may be present in some vehicles. Remove the weld as necessary for the section repair.
  6. Cut the new Side Sill as indicated below to make the new component.

    Cut Line

    Reference Line/Point

    • C = 80 mm.
    • D = 70 mm.
  7. Grind down the rib highlighted in red to provide a flat space to mount a backing plate.
  8. Remove the rivnut from the new component.
  9. Cut a section of the new Side Sill as indicated below to make backing plates for the new component.

    Cut Line

    Reference Line/Point

    • E = 160 mm.
    • F = 85 mm.
  10. Trim the purchased cell backing plates to length.
    • Upper Cell Lower Back Plate: Trim to 160 mm.
    • Upper Cell Upper Backing Plate: Trim to 160 mm.
    • Middle Cell Backing Plate: Trim to 160 mm.
    • Lower Cell Backing Plate: Trim to 150 mm.
  11. Grind the inboard surface of the middle cell flat to provide an area to mount a backing plate.
    • G = 80 mm.
  12. Position the inboard backing plates for the upper cell and the middle cell, and clamp them in place.
  13. Drill an 11 mm. hole in the upper cell upper backing plate for a Rivnut in the indicated location.
  14. Drill 8 mm. holes for hex-head bolts through the factory bosses (circled in red) in the Rear Node and through the Side Sill backing plates.
  15. Remove the Side Sill backing plates.
  16. Enlarge the 8 mm. holes created in a previous step to 11.5 mm.
  17. Apply adhesive to the back of the SPAC nuts, position them in the backing plates, and clamp them in place.
  18. Install the Rivnut in the Upper Cell Upper Backing Plate.
    Rivnut
  19. Install backing plates on the vehicle.

    or High Strength Structural Rivets, 6.5 mm

    or Bolts, hex-head

  20. Prepare for installation.
    or High Strength Structural Rivets, 6.5 mm

    or Structural Countersunk Rivets, 6.5 mm

    GMA Weld

  21. Drill out any existing holes that are obstructed by backing plates.
  22. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  23. Install the new component or components.
    Torque all bolts to 25 Nm.
  24. Perform GMA welding.
    Informational PurposesAn informational icon, calling your attention
    Note
    Grind down the welds on the lower flange and the inboard vertical side of the Sill until they are flush with the surrounding panels.

    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.
  25. Install the Sill Nut Strip.
    or Pop Rivets
  26. Install the Rear Node Upper Reinforcement (Front).
  27. Install the C–Pillar Reinforcement.
  28. Install the Wheelhouse Extension.
  29. Perform any necessary post-repair operations.