Torque Box Inner Repair Guidelines

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

The images below show the Torque Box Inner from different angles, and contain highlighted areas. Compare the damaged area of the vehicle's Torque Box Inner 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.

Torque Box Inner – Top View (LH)

Torque Box Inner – Top View (RH)

Torque Box Inner – Bottom View (LH)

Torque Box Inner – Bottom View (RH)

Torque Box Inner – Inboard View (LH)

Torque Box Inner – Inboard View (RH)

Torque Box Inner – Outboard View (LH)

Torque Box Inner – Outboard View (RH)

Torque Box Inner – Outboard ISO View (LH)

Torque Box Inner – Outboard ISO View (RH)

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

Table 1. Allowed Repairs
Area Color Allowed Repairs

Orange areas:

  • For damage up to 40 mm. in length, heat and straighten damage.
  • Smooth sharp edges.
  • Rebuild flange with welding wire. See Rebuild the Flange with Welding Wire for more information.
  • Install a reinforcement plate (Tesla part number 1076938-E0-B). See Installing a Reinforcement Plate for more information.
  • For damage more than 40 mm. in length, the component is not repairable.

Red areas:

None; if the Torque Box Inner is damaged in these areas, contact Tesla Collision Repair for assistance.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
When welding on the cast Rear Under Body, use only approved aluminum welding wire, as specified in Approved Gas Metal Arc (GMA) Welders and Welding Wire.

Rebuild the Flange with Welding Wire

Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.

  1. Use a heat gun to heat the damaged area.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not heat any adhesive joints of components that are not being removed. Heating adhesive joints weakens the adhesive bond and could compromise vehicle crash integrity.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not heat the adhesive on a bonded panel above 100°C (212°F) unless that panel is being removed. Heating the adhesive above 100°C (212°F) can weaken the adhesive bond and compromise vehicle crash integrity.
  2. Use a hammer and dolly or pliers to straighten the damaged area.
  3. Remove material containing cracks and smooth any remaining sharp edges in the repair area.
    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.
  4. Use dye penetrant on the repair area to check for micro cracks in the aluminum.
    Informational PurposesAn informational icon, calling your attention
    Note
    If a crack is found, refer to the Repair Criteria above to determine what level of repair is required.
  5. Remove any factory self-piercing rivets present in the weld repair area.
  6. Use a disc or belt sander with a surface conditioning abrasive product to remove all coatings in the immediate vicinity of the weld locations.
    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.
  7. MIG weld the flange area, adding enough material to restore the flange to factory dimensions.
  8. Grind down welds to restore all components to their original dimensions.

Installing a Reinforcement Plate

Reinforcement plates may be installed on the Torque Box Inner flange only as specified in the Allowed Repairs table (above) or at the direction of the Tesla Collision Repair Support Team.
Informational PurposesAn informational icon, calling your attention
Note
Reinforcement plates on the Torque Box Inner flange are not installed by welding; reinforcement plates are installed only with structural adhesive and rivets.

Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.

The following parts are required:

Quantity Description Image / Notes
1 PLATE- SERVICE SIDE SILL ECOATED (Side Sill Reinforcement Plate)
2 Structural Rivet, 6.5 mm Short
Reinforcement plates on the Torque Box Inner flange are installed as follows:
  1. Remove the Torque Box Outer.
  2. Straighten the area where the reinforcement plate will be installed.
    Informational PurposesAn informational icon, calling your attention
    Note
    The reinforcement plate will be installed behind the repair area of the flange according to the Repair Criteria.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not heat any adhesive joints of components that are not being removed. Heating adhesive joints weakens the adhesive bond and could compromise vehicle crash integrity.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not heat the adhesive on a bonded panel above 100°C (212°F) unless that panel is being removed. Heating the adhesive above 100°C (212°F) can weaken the adhesive bond and compromise vehicle crash integrity.
  3. If needed, repair the metal in the area where the reinforcement plate is to be installed. See Rebuild the Flange with Welding Wire for more information.
  4. Fabricate a reinforcement plate from the side sill backing plate similar to the one shown here.

    Informational PurposesAn informational icon, calling your attention
    Note
    The reinforcement plate must extend at least 25 mm beyond both edges of the repair area and must fit snugly against the back side of the flange.
  5. Trim and rework the reinforcement plate as necessary to snugly fit over the area to be reinforced, and allow for any adjoining panels.
  6. Clamp the reinforcement plate in position behind the repair area of the flange according to the Repair Criteria.
  7. Position the Torque Box Outer.
  8. Create 6.7 mm. holes for the structural rivets.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not install rivets in the repair area or within 13 mm. of the edges of the repaired area.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rivets locations securing the reinforcement plate must not interfere with rivets used for installing the Torque Box Outer.
  9. Prepare the Torque Box Outer for installation as directed.
    Informational PurposesAn informational icon, calling your attention
    Note
    When preparing the Torque Box Outer for installation, do not drill holes for rivets in the repaired area.
  10. Prepare the surfaces for adhesive. See Preparing Mating Surfaces for Adhesives (Non–Welded Components) for more information.
  11. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  12. Put the Torque Box Outer and fabricated reinforcement plate in position and secure them in place.

  13. Install the fasteners in the Torque Box Outer.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    When installing fasteners in the Torque Box Outer, do not install structural rivets in the repaired area.
  14. Install the rivets in the reinforcement plate.

    or Structural Rivets, 6.5 mm Short

  15. Complete the installation of the Torque Box Outer.