Replacing Broken Front Frame Rail Studs

Instructions for replacing broken or missing front frame rail studs.

If a front frame rail stud breaks off during shipment or during a repair, weld the original stud back on if possible. If the original stud did not break off cleanly (i.e., there is a substantial piece of the original stud remaining on the rail) or if the original stud is missing, order a replacement stud and weld it on in the original location.

Replacement Studs

Front frame rails have 3 types of studs:

  • M8 ground studs (circled in green)
  • M6 mounting studs (circled in yellow)
  • Studs for push clips (circled in red)
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Note
The images shown are provided as an example. The quantity and exact location of studs might vary.

Use the table below to order the correct replacement stud.

Stud Image Tesla P/N QTY Parts Manual Description
M8 Ground Stud
2007130-00-A 1 WELD STUD - ALUMINUM M8-1.25x26
M6 Mounting Stud
1013806-00-A 1 STUD,WLD,RND,M6-29.5[AL]CO
Stud for Push Clips
2007122-00-A 1 STUD WLD AL FLG T5x15.5
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Note
These part numbers were current at the time of publication. Use the revisions listed or later, unless otherwise specified in the Parts Manual.

Procedure

  1. Use a grinding tool to grind off the remaining piece of the stud.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Use only sanding wheels and belts that are 80 grit or finer on aluminum components. Using sanding wheels or belts that are coarser than 80 grit can cause fractures in the aluminum.
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    Warning
    Remove the e-coat in a well-ventilated area. Wear suitable personal protective equipment.
  2. If necessary, use a disc sander with a medium-abrasive surface conditioning disc or a belt sander with a medium-abrasive belt to remove the e-coat on the front frame rail in the weld area.
  3. GMA weld the stud to the front frame rail.
    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.
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    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.
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    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.
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    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.
  4. Prime any bare metal with a suitable corrosion-resistant primer.