03/07/2024 16:03:52

Sill (Front Section)

Repair Information

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	FRONT SILL SECTION KIT (Sill - Front Section Kit)
	Front Sill Complete Section
	Upper Cell Lower Backing Plate
	Upper Cell Upper Backing Plate
	Lower Cell Backing Plate
	Middle Cell Backing Plate
16	Structural Countersunk Rivet, 6.5 mm
11	Structural Bulb Rivet, 6.5 mm
3	Structural Rivet, 6.5 mm Medium
3	Pop Rivets, 4.8 mm
9	Rivnut, M6 - 1.00x3
2	Rivnut, M8 - 1.25x3

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 necessary portion of the Hinge Pillar Assembly.
Remove the Front Frame Rail Outer Extension Reinforcement.
Remove the Torque Box Plate.
Remove the Sill Nut Strip.
or Factory Structural Rivets
Remove the Sill Insert.
or Factory Structural Rivets
Rivnut
Remove the original component.
Cut Line

Reference Line/Point
- A = 228 mm.
- B = 214 mm.
Rivnut

GMA Weld
Note
An additional weld may be present in some vehicles remove the weld as necessary for the section repair.
Test fit the new component and trim to fit.
- C = 190 mm.
Create and install a backing plate on the replacement component.

Note
Trim the supplied backing plate to 90 mm.
or Structural Bulb Rivets, 6.5 mm
Create and install backing plates on the vehicle.

Note
Trim the supplied backing plates to 90 mm.
or Structural Bulb Rivets, 6.5 mm
or Structural Countersunk Rivets, 6.5 mm
Prepare for installation.
or Structural Bulb Rivets, 6.5 mm
or Structural Countersunk Rivets, 6.5 mm

GMA Weld
Drill out any existing holes that are obstructed by backing plates.
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.

Note
Grind down the welds on the lower flange, Torque Box to Sill joint, and the inboard vertical Sill until they are flush with the surrounding panels.

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 Sill Insert.
or Structural Rivets, 6.5 mm Medium
Install the rivnuts in the Sill Insert and Sill Front Section.
Rivnut
Install the Sill Nut Strip.
or Pop Rivets, 4.8 mm
Install the Torque Box Plate.
Install the Front Frame Rail Outer Extension Reinforcement.
Install the Wheelhouse Extension.
Install portion of the Hinge Pillar Assembly that was removed to expose the component being replaced.
Perform any necessary post-repair operations.