2025-03-13

Front Frame Rail Complete

Parts List

Quantity Description Image / Notes
1 ASSEMBLY - FRONT RAIL (Front Frame Rail Complete)
1 PNL, LONGITUDINAL UPPER (Longitudinal Upper)
42 High Strength Structural Rivet, 6.5 mm
28 Structural Bulb Rivet, 6.5 mm
10 Countersunk Rivet, 4.8 mm Short
3 Countersunk Rivet, 4.8 mm Long
1 Rivet, 4.8 mm
1 Flow Form Rivet S38
4 Bolt , BLT,M8x16,M6 HF,[10.9],ZnAl,HD,OD14.9 Tesla part number 1011818-00-A.
4 Nut , NUT,M8-1.25,HF,Steel[10],ZnAl,BLACK Tesla part number 1006628-01-A.

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

  1. Remove the Shotgun Outer.
  2. Remove the Dash Crossmember.
  3. Remove the Front Subframe Support.
  4. Remove the original component.
    or Factory Spot Welds
    or Drill through factory spot welds
    Informational PurposesAn informational icon, calling your attention
    Note
    When drilling out spot welds, use a drill bit that creates a hole correctly sized for the fastener that will replace the spot weld.
  5. Prepare to install the Longitudinal Upper on the Front Frame Rail Service part.
    or High Strength Structural Rivets, 6.5 mm
    • A = 73 mm
    • B = 63 mm

    or Rivets, 4.8 mm

    or Installation Spot Welds

  6. Apply structural adhesive to the Longitudinal Upper and the Front Frame Rail Service part.
  7. Install the Longitudinal Upper on the Front Frame Rail Service part.
  8. Perform resistance spot welding.
    or Installation Spot Welds
    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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    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.
  9. Prepare for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    A red X indicates a location where a factory-installed fastener is not being replaced.

    or High Strength Structural Rivets, 6.5 mm

    or Structural Bulb Rivets, 6.5 mm

    or Countersunk Rivets, 4.8 mm Short
    Informational PurposesAn informational icon, calling your attention
    Note
    The installation location for some rivets is offset from the location of some factory spot weld locations.

    or Countersunk Rivets, 4.8 mm Long

    or Flow Form Rivets, S38

    or Bolts
    • C = 10 mm
    • D = 9 mm

    Nut

  10. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
  11. Install the new component or components.
    Torque the bolts to 22 Nm.
  12. Remove/Install the Front Subframe Support.
  13. Install the Dash Crossmember.
  14. Install the Shotgun Outer.
  15. Install the butyl patch as shown.
  16. Perform any necessary post-repair operations.