Approved Fasteners and Fastener Tools for Structural Repairs

Describes the fasteners and fastener tools approved for use in structural repairs on Tesla vehicles.

The following fasteners are approved for structural repairs on Tesla vehicles:
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Warning
Use only approved fasteners sourced from Tesla when performing structural repairs on Tesla vehicles. The use of non-approved fasteners might compromise the integrity of the repair and vehicle safety, as well as affecting whether Tesla supports the vehicle.

Refer to Approved Fastener Installation Tools for information on the tools used to install fasteners.

Standard Rivets

Standard Rivet Information
Fastener Type Fastener Symbol Fastener Path Symbol Part Name Part Number
Rivet, 4.8 mm RIVET, 4.8MM, 1.6 - 6.9MM 1028719-00-A
Structural Rivet, 6.5 mm short RIVET, 6.5MM, 2.0 - 9.5MM 1028408-00-A
Structural Rivet, 6.5 mm medium STR.CMMN RIV 6.5 STL ZN 3-13.5 1062559-00-A
Structural Rivet, 6.5 mm long RIVET, 6.5MM, 2.0-15.9MM 1028409-00-A
Structural Rivet, 6.5 mm (High Strength) HIGH STRENGTH RIVET 6.5MM, 2.6MM - 9.5MM 1454538-00-A
Pop Rivet (Aluminum, domed head) BLD RIV 5/32,0.126-0.187,AL/STL,DOMED 1003668-00-C
All standard rivets can be installed with a standard rivet gun, except for the 8 mm (5/16 in) structural rivet.
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Note
Rivet guns used in Tesla repair procedures must have a pulling force of at least 14,000N (3,000 LBF).
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For information about installing these fasteners, refer to the Preparing for Fastener Installation section of Preparing for Installation.

To install 8 mm (5/16 in) structural rivets, use one of the tools listed in the Approved Fastener Installation Tools section of this document along with the appropriate attachments listed below.

Tool
XPress ProSpot Huck
Attachment to Use BR-80 attachment with Huck nose 99-3307 PR-PA20 + PPA-N5 Huck nose 99-3307

Countersunk Rivets

Countersunk rivets are used in situations where the rivet head needs to sit flush with the body panel.

Countersunk Rivet Information
Fastener Type Fastener Symbol Fastener Path Symbol Part Name Part Number
Countersunk Rivet, 4.8 mm short SM CTSK RVT,4.8 ALU/STL2.0-3.1MM 1069308-00-A

or

2046255-00-A
Structural Countersunk Rivet, 4.8 mm long STRUCTURAL COUNTERSUNK RIVET, 4.8MM (3/16") KIT, ALUMINUM BODY/STEEL STEM, GRIP RANGE 3.18-8.41MM 1069326-00-A
Structural Countersunk Rivet, 6.5 mm STRUCTURAL COUNTERSUNK RIVET, 6.5MM (1/4") KIT, ALUMINUM BODY/STEEL STEM, GRIP RANGE 4.06-12.07MM 1069327-00-A

Use the Microstop Countersink kit (Tesla part number 1133101-00-A) to countersink the holes before installing the countersunk rivets. Adjust the depth of the tool so that the head of the rivet is flush with the surrounding panel. Refer to Microstop Countersink Kit for more information.

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Note
For information about installing these fasteners, refer to the Preparing for Fastener Installation section of Preparing for Installation.

Structural Bulb Rivet

Structural bulb rivets are used where clearance with trim is an issue or when replacing a short rivet, as the back portion of the bulb rivet is smaller than a regular structural rivet. Structural bulb rivets can typically be used in thin sheet metal applications where the total thickness of the panels is 4.5 mm or less.

Structural Bulb Rivet Information
Fastener Type Fastener Symbol Fastener Path Symbol Part Name Part Number
Structural Bulb Rivet, 6.5 mm STR. BULB RIV6.5 STL ZN 2-4.5 1063943-00-A
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Note
For information about installing these fasteners, refer to the Preparing for Fastener Installation section of Preparing for Installation.

Structural Flange Rivet

Structural flange rivets are used where the hole in the part is too large for a conventional rivet head.

Structural Flange Rivet Information
Fastener Type Fastener Symbol Fastener Path Symbol Part Name Part Number
Structural Flange Rivet, 6.5 mm LRG FLNG RIV6.5 STL ZN 2-15.9 1062558-00-A
Structural Flange Rivet, 6.5 mm (High Strength) RIVET STRCTR,1/4x0.1-0.375,STL,ZN 1116094-00-A
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Note
For information about installing these fasteners, refer to the Preparing for Fastener Installation section of Preparing for Installation.

Self-Piercing Rivets

Self-piercing rivets (SPRs) are designed to be used in applications where the total number of panels is 3 or less. Whenever possible, install SPRs so that the SPR goes through the thinner panel first.

Self-Piercing Rivet Information
Fastener Type Fastener Symbol Fastener Path Symbol Part Name Part Number
SPR, 5x4 SPR Rivet C 5x4 H4 SKR 1026936-00-A
SPR, 5x4.5 SPR Rivet C 5x4.5 H4 SKR 1026938-00-A
SPR, 5x5 SPR Rivet C 5x5 H4 SKR 1026939-00-A
SPR, 5x6 H4 SPR Rivet C 5x6 H4 SKR 1026940-00-A
SPR, 5x6 H2 SPR Rivet C 5x6 H2 SKR 1026941-00-A
SPR, 5x6.5 SPR Rivet C 5x6.5 H4 SKR 1026942-00-A
SPR, 5x7 SPR Rivet C 5x7 H4 SKR 1026943-00-A
SPR, 5x8 SKR SPR Rivet K 5x8 H4 SKR 1026944-00-A
SPR, 5x8 SK SPR Rivet P 5x8 H4 SK 1026945-00-A
SPR, 5x9 SPR Rivet K 5x9 H4 SKR 1028629-00-A

To install SPRs, use one of the tools listed in the Approved Fastener Installation Tools section of this document along with the appropriate die. For the ProSpot tool, use table below to determine the appropriate die based on the Böllhoff die listed in the Body Repair Manual procedure.

Tool
Böllhoff (Use Die Specified in Procedure) ProSpot (Use Die Corresponding to Böllhoff Die Specified in Procedure)

 XPress
SPR Die to Use SM 110 0108 T1 F5 adaptor with the Böllhoff die specified in the procedure
SM 085 0125 T2
FM 090 2120 T3
KA 075 2113 T4
SM 070 0056 T5
FM 100 2022 T6
SM 120 0050 T7

Flow Form Rivets

For areas likely to have repeat repairs, flow form rivets can be used in place of SPRs so that additional holes do not have to be created in the body panel(s). Refer to Using Flow Form Rivets for more information.

Flow Form Rivet Information
Fastener Type Fastener Symbol Fastener Path Symbol Part Name Part Number
Flow Form Rivet, S08 Flw Frm Rvt,S08-8mmSt.Stl 1.3-2.5 1069328-00-A
Flow Form Rivet, S18 Flw Frm Rvt,S18-8mmSt.Stl 2.3-3.5 1069329-00-A
Flow Form Rivet, S28 Flw Frm Rvt,S28-8mmSt.Stl3.35-4.10 1069330-00-A
Flow Form Rivet, S38 Flw Frm Rvt,S38-8mmSt.Stl 4.0-5.15 1069331-00-A
Flow Form Rivet, S48 Flw Frm Rvt,S48-8mmSt.Stl 5.0-6.1 1069332-00-A
Flow Form Rivet, S58 Flw Frm Rvt,S58-8mmSt.Stl 6.0-7.2 1069333-00-A
Flow Form Rivet, S68 Flw Frm Rvt,S68-8mmSt.Stl 7.1-8.3 1069334-00-A

To install flow form rivets, use one of the tools listed in the Approved Fastener Installation Tools section of this document along with the appropriate die and at the installation pressure listed below.

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Note
The C3, C4, and C5 dies for use with the XPress and the TKR riveters are available from Wieländer + Schill.
Flow Form Rivet Size Tool
XPress Bollhoff TKR ProSpot
Flow Form Rivet Dies to Use S08 and S18 C5 holding die with a C4 forming die Flow Form Punch Assembly (55003226514) with Flow Form Die (95300285166) C5 holding die with a C4 forming die FF-8-1 holding die with an FF-8-2 forming die
S28–S68 C3 holding die with a C4 forming die Flow Form Punch Assembly (55003226514) with Flow Form Die (95300285166) C3 holding die with a C4 forming die FF-8-3 holding die with an FF-8-2 forming die
Installation Pressure (kN) N/A 60 50 60 50
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For information about installing these fasteners, refer to the Preparing for Fastener Installation section of Preparing for Installation.

BOMs and 8 mm Structural Rivets

BOMs (blind, oversize mechanically locked fastener) are available in 5/16 in diameter and structural rivets are 8 mm in diameter.

BOM and 8 mm Structural Rivet Information
Fastener Type Fastener Symbol Fastener Path Part Name Part Number
BOM, 5/16 in N/A BOM5/16 STL ZINC GRIP7.95-11.1 1062555-00-A
8 mm Structural Rivets BLIND RIVET 5/16X4.0-7.0 GRIP STL ZN 1058710-00-A
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For information about installing these fasteners, refer to the Preparing for Fastener Installation section of Preparing for Installation.

To install BOMs, use one of the tools listed in the Approved Fastener Installation Tools section of this document along with the appropriate attachment listed below.

Tool
XPress ProSpot Huck
Attachment to Use BR-80 attachment with Huck nose 99-769 PR-PA38-BOM Huck nose 99-769

NeoBolts and AVBolts

NeoBolts and AV Bolt Rivets are available in 3/4 and 5/8 in diameter.

NeoBolt Information
Fastener Type Fastener Symbol Part Name Part Number Grip Range
NeoBolt Neo Bolt, 3/4 in, Short 1599680-00-A 12.7-22.1 mm.
COLLAR,NEOBOLT,3/4 1599682-00-A N/A
Neo Bolt, 3/4 in, Long 1599681-00-A 25.4-34.8 mm.
COLLAR,NEOBOLT,3/4 1599682-00-A N/A
Neo Bolt, 5/8 in 1599677-00-A 4.9-15.7 mm.
COLLAR,NEOBOLT,5/8 1599679-00-A N/A
AV Bolt Rivet N/A Avbolt Rivet, 5/8 in 1600794-00 12.7-19.05 mm.

To install NeoBolts, use one of the tools listed in the Approved Fastener Installation Tools section of this document.

Pin and Collars

Pin and collar fasteners are available in 1/4 in and 5/16 in diameters.

Pin and Collar Information
Fastener Type Fastener Symbol Part Name Part Number
Pin and Collar, 1/4 in PIN&COLLAR 1/4 STL ZINC 1.6-15.9 1062557-00-A
Pin and Collar, 5/16 in PIN&COLLAR5/16 STL ZNC 3.2-19.1 1062556-00-A

To install pin and collars, use one of the tools listed in the Approved Fastener Installation Tools section of this document along with the appropriate attachment listed below.

Pin and Collar Size Tool
XPress Huck
Attachment to Use 1/4 in BR-80 attachment with Huck nose 99-3207 Huck nose 99-3207
5/16 in BR-80 attachment with Huck nose 99-1439 Huck nose 99-1439

Bolts and Nuts

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Note
When ordering Bolts and Nuts, order the number of each type of bolt or nut specified in the repair procedure.
Bolts and Nuts Individual Fastener Symbol Fastener Path Symbol Part Number
Bolt Varies, depending on specific fastener specified in the repair procedure.
Bolt, Torx-head
Bolt, Allen-head
Nut

Rivet Studs

To install the rivet stud, use any tool capable of properly installing the specified fastener.

Individual Fastener Symbol Fastener Path Symbol Part Number
Rivet Studs Varies, depending on specific fastener specified in the repair procedure.

Approved Fastener Installation Tools

Use the table below to determine which of the approved fastener installation tools can be used to install which types of approved fasteners.

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Note
Additional attachments and fittings might be necessary for some of these tools to install certain fasteners. Refer to the appropriate section for the specific fastener type, or contact your tool distributor for more information.
Fastener Installation Tool Fasteners
SPRs

 Flow Form Rivets

 BOMs and 8 mm Structural Rivets

 Pin and Collars

 4.8 mm and 6.5 mm Structural and Countersunk Rivets

 NeoBolts and AV Bolts

XPress 800 Tool
ProSpot PR-5
ProSpot PR-5D
Huck 254 Pneudraulic Installation Tool
Böllhoff HTF 50 SPR Tool
TKR PNP 90 UN 2.0
TKR PNP 90 XT²
Stanley AV25
Gesipa PowerBird Pro (shown with Angle Head 90°)
  • Approved
  • Not Approved