Torque Box Outer Repair Guidelines

Explains how to determine if the Torque Box Outer can be repaired or if replacement is required.

The images below show the Torque Box Outer from different angles, and contain highlighted areas. Compare the damaged area of the vehicle's Torque Box Outer to the images below, then use the repair criteria corresponding to the color of the highlighted area to find the criteria to use to determine if the damaged area of the component can be repaired.

View LH Component RH Component
Inboard
Outboard

Based on the colors used in the images above, the allowed repairs are as follows:

Table 1. Allowed Repairs
Area Color Allowed Repairs

Green areas:

  • Repairing damage up to 25 mm is allowed.
  • For damage more than 25 mm in length, contact Tesla Collision Repair for assistance.
  • Bent flange sections may be straightened using hot or cold methods.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not heat structural adhesive to 100° C or (212° F).

Red areas:

None; if the component is damaged in these areas, contact Tesla Collision Repair for assistance.

Repairing Torque Box Flange Damage

  1. Straighten the damaged area using hot or cold methods.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not heat the adhesive joints above 100°C (212°F). Heating the adhesive joints above 100°C (212°F) can weaken the aluminum and compromise vehicle crash integrity.
    Informational PurposesAn informational icon, calling your attention
    Note
    If material breaks off when attempting to straighten the damaged area, the missing area can be built back up during welding.
  2. If the factory self-piercing rivet (SPR) is still present, remove the SPR.
  3. In the repair area, remove any adhesive between the Front Torque Box and the Front Torque Box Cover.
  4. Prepare the area for GMA welding.
  5. Perform GMA welding as necessary:
    • Flange area
    • Fill in the area where the factory self-piercing rivet was originally located
    • Any cracks
  6. Grind down the welds and restore all the components to their original dimensions.
  7. Prime any bare metal with a suitable corrosion-resistant primer.