2025-06-12

Quarter Outer Assembly (Without Upper Trough)

Repair Information

Note

If the repair area includes any portion of the Roof Rail, do not use this procedure; instead, refer to the Body Side Outer.

Any individual section or any combination of sections of the Body Side Outer Assembly can be replaced so long as the Sectioning Guidelines are followed.
Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.
This procedure can be completed without using a frame bench.

Using this Document

This document contains two major parts:

Sectioning Guidelines provides information on where and how to section the Quarter Outer Assembly as necessary to replace damaged areas of the Quarter Outer assembly, or to gain access to underlying parts of the vehicle structure. Use the guidelines to determine where to successfully section the Quarter Outer Assembly as needed for the repair being performed.
The Repair Procedure portion of this document contain the information necessary to replace the entire Quarter Outer Assembly. If replacing sections of the Quarter Outer (not the entire Quarter Outer Assembly), use the relevant portions of each step to determine which parts and fasteners are needed and the steps required to complete the repair.

Parts List


Quantity	Description	Image / Notes
1	REAR QUARTER OUTER ASY (Rear Quarter Outer Assembly)
2	Structural Bulb Rivet, 6.5 mm
11	Flow Form Rivet S18

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.

Sectioning Guidelines

General sectioning guidelines:

If a section repair requires the removal or installation of additional panels or assemblies, perform the necessary procedures using the specific repair procedure for each panel or assembly.
It is allowable to cut through a clearance hole or a non functional hole (exterior trim hole), as described below.
Do not cut within 25 mm. of the center of a bolt hole.
Sections do not require fasteners at butt joints unless specifically indicated.
A backing plate may be installed at a butt joint between sections (as described in create and install backing plates).
Gaps between panels of butt joints should be as small as possible to maximize joint strength.
GMA weld section butt joints.
Seal all open seams after welding.
If a butt joint includes a flange, do not weld on the flange (flanges are secured using only structural adhesive).

Note

Do not cut underlying panels when sectioning the Quarter Outer Assembly.

The images below show the Quarter Outer Assembly sections. The colored areas indicate if sectioning is allowed. Compare the damaged area of the vehicle's Quarter Outer Assembly 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 sectioned.


Quarter Outer Assembly Sectioning

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

Table 1. Allowed Sectioning
Area Color	Area Repairability
Green areas:	Sectioning is allowed in these areas.
Yellow areas:	Sectioning is allowed in these areas. Foam is located behind the panel. Note If sectioning in this area, remove the foam and then clean the area to avoid weld contamination.
Red areas:	Sectioning is not allowed.

Repair Procedure

Remove the Upper Trough from the Rear Quarter Outer Assembly service part.
- or Drill through factory spot welds
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.
- or Factory Spot Welds
Remove the Upper Trough from the Rear Quarter Outer Assembly service part.
- or Drill through factory spot welds
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.
- or Factory Spot Welds
Remove the Upper Trough from the Rear Quarter Outer Assembly service part.
- or Factory Spot Welds
Remove the original component.
- or Factory Spot Welds
- or Factory SPRs
Remove the original component.
- or Drill through factory spot welds
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.
- or Factory Spot Welds
- or Factory SPRs
Remove the original component.
- or Drill through factory spot welds
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.
- or Factory Spot Welds
- or Factory SPRs
Remove the original component.
- or Factory Spot Welds
Remove the original component.
- or Factory Spot Welds
Prepare for installation.
Note
A red X indicates a location where a factory-installed fastener is not being replaced.
- or Structural Bulb Rivets, 6.5 mm
- or Flow Form Rivets, S18
- GMA Weld
- or Installation Spot Welds
Prepare for installation.
Note
A red X indicates a location where a factory-installed fastener is not being replaced.
- or Structural Bulb Rivets, 6.5 mm
- or Flow Form Rivets, S18
- GMA Weld
- or Installation Spot Welds
- or Steel Plug Welds
Prepare for installation.
Note
A red X indicates a location where a factory-installed fastener is not being replaced.
- or Flow Form Rivets, S18
- or Installation Spot Welds
- or Steel Plug Welds
Prepare for installation.
Note
A red X indicates a location where a factory-installed fastener is not being replaced.
- or Flow Form Rivets, S18
- or Installation Spot Welds
- or Steel Plug Welds
Prepare for installation.
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
Install the new component or components.
Perform resistance spot welding.
- or Installation Spot Welds
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.

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.
Perform GMA welding.
- or Steel Plug Welds
- GMA Weld
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
To maintain vehicle crash integrity, use only approved welding wire and an approved GMA welder to perform GMA welding on Tesla vehicles. Refer to Approved Gas Metal Arc (GMA) Welders and Welding Wire for information on approved GMA welders and welding wire.

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.

Note
Before GMA welding, a test weld using material of the same gauge and type should be performed to make sure that the welding equipment settings produce a satisfactory joint.
Perform any necessary post-repair operations.