13/11/2024 16:30:35

Cast Rear Under Body (1–Piece)

Repair Information

Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.
Depending on the damage to this component, it may be possible to repair this component. Refer to Cast Rear Under Body (1–Piece) Repair Guidelines for more information.
Properly mount the vehicle on a frame bench when performing this procedure.

Parts List


Quantity	Description	Image / Notes
1	CAST RUB-SP E-COATED (Rear Under Body 1–Piece)
1	ASSEMBLY - EXTENSION REAR WHEEL HOUSE - LEFT HAND SERVICE E-COATED (Wheelhouse Extension – Front – LH)
1	ASSEMBLY - EXTENSION REAR WHEELHOUSE - RIGHT HAND SERVICE E-COATED (Wheelhouse Extension – Front – RH)
21	High Strength Structural Rivet, 6.5 mm
12	Rivet, 4.8 mm
4	Bolt , HF,M6x20,[88],ZNFL,MAT	Tesla part number 1120935-00-A.
10	Bolt , BOLT&WSHR[FL],M8-1.25x32	Tesla part number 1119448-00-A.
2	Rivnut, FH,M8,3.5-5.5,[10],ZN	Tesla part number 1469780-00-B.

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 LH and RH Rear Panel Side Assembly (for 1–Piece Cast Under Body).
Remove the LH and RH Wing Bracket (Lower).
Create an access window in the Wheelhouse Extension (Front).
- A = 50 mm.
- B = 130 mm.
- C = 75 mm.
- D = 21 mm.
Cut the new Wheelhouse Extension components to create LH and RH access window covers.
The finished cover should be approximately 32 mm. wider and 10 mm. taller than the access window. Black dashed lines indicate the the access window.
Note
When positioned poperly, the cover overlaps the top, bottom, and inboard edges of the access window by 5 mm . The cover also overlaps the outboard edge of the access window by 27 mm.
- E = 82 mm.
- F = 140 mm.
Remove the Rivnut from the new component.
Rivnut
Remove the original component.

or Factory Spot Welds

or Factory SPRs

Rivnut

or Bolts
Install the rivnut in the Door Ring Inner.
Rivnut
Note
The Rivnut is installed from inside the vehicle.
Prepare for installation.
Note
A red X indicates a location where a factory-installed fastener is not being replaced.
or Rivets, 4.8 mm
- G = 79 mm.
- H = 24 mm.
- I = 28 mm.
- J = 26 mm.
or High Strength Structural Rivets, 6.5 mm
- K = 17 mm.
or Bolts
Note
The bolt in circled in red is replaced only if it was present on the original component.
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
Install the new component or components.
Torque bolts as follows:
- Bolts vertically installed in the Sill: 35 Nm.
- Bolts horizontally installed in the Sill: 31 Nm.
- Bolts securing the Floor Crossmember to the Cast Rear Under Body (Tesla part number 1120935-00-A): 28 Nm.
Install the LH and RH Rear Rail End Plate (For 1–Piece Cast Under Body).
Install the LH and RH Wing Bracket (Lower).
Prepare to install the Access Window Covers.

or Rivets, 4.8 mm

Note
When positioned poperly, the cover overlaps the top, bottom, and inboard edges of the access window by 5 mm . The cover also overlaps the outboard edge of the access window by 27 mm.
Apply structural adhesive to the mating surfaces on the vehicle and the Access Window Covers.
Install the Access Window Covers.
Install the Rear Panel Side Assembly (for 1–Piece Cast Under Body).
Perform any necessary post-repair operations.