2025-09-10

Rear Rail (Cast)

Correction code: 10102100702 10102100602 NOTE: Unless explicitly stated in the procedure, the above correction code includes all Collision Repair work required to perform this procedure, including the linked Collision Repair procedures. Do not stack Collision Repair correction codes unless explicitly told to do so. Add any associated mechanical procedures needed to perform this procedure.

Repair Information

Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.
Properly mount the vehicle on a frame bench when performing this procedure.

Parts List


Quantity	Description	Image / Notes
1	CASTING REAR RAIL SERVICE ASSEMBLY (Rear Frame Rail - Small Section)
1	BUTYL FOIL PATCH - M3 480 X 240 X 2.0 (Butyl foil patch)	Tesla part number 1004964-00-A.
5	High Strength Structural Rivet, 6.5 mm
4	Bolt, Torx-head , M8X22,STL[10.9],PC	Tesla part number 1056534-00-C.
4	Nut , HEX,FLGS,M8-1.25X18.2[8]-TBD	Tesla part number 1014348-00-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

Remove the Rear Panel Side Assembly.
Remove the Wing Bracket (Lower).
Remove the original component.
- Cut Line
Note
Cut just to the rear of the cast cut line on the original component, then trim the original component as necessary to fit. Keep any gaps as small as possible.
Trim the service part in the indicated area.

Lightly grind and smooth the edges of the service part in the area shown in red, and trim only as needed to ensure proper fitment. Do not grind more material than necessary, and do not cause a gap. Grinding may extend beyond the indicated area if necessary.
Note
Keep the amount of material removed to the minimum necessary for proper fitment of the service part without introducing a gap. If a gap results from excessive grinding, contact Tesla Collision Repair for assistance.
Prepare for installation.
- Reference Line/Point
- Bolt, Torx-head A = 109 mm B = 153 mm C = 35 mm D = 34 mm
Prepare for installation.
- Bolt, Torx-head
Note
Install the outboard bolts using the same measurements as used to install the inboard bolts.
Prepare for installation.
- or High Strength Structural Rivets, 6.5 mm
- Bolt, Torx-head
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
Install the new component or components.
Torque the bolts to 48 Nm.
Apply seam sealer to the joint between the new component and the Cast Rear Under Body.
Prepare to install the rivets that secure the Rear Rail End Plate to the Rear Rail.
- Reference Line/Point
- or High Strength Structural Rivets, 6.5 mm E = 15 mm F = 30 mm
Prepare to install the rivets that secure the Rear Rail End Plate to the Rear Rail.
- Reference Line/Point
- or High Strength Structural Rivets, 6.5 mm E = 15 mm F = 30 mm G = 80 mm
If the new component does not have structural adhesive securing the Rear Rail End Plate to the Rear Rail: Remove the Rear Rail End Plate.

Note
Retain the Rear Rail End Plate (it is installed in a later step).
If the new component does not have structural adhesive securing the Rear Rail End Plate to the Rear Rail: Apply structural adhesive to the mating surfaces on the Rear Rail End Plate and the Rear Rail.
If the new component did not have structural adhesive securing the Rear Rail End Plate to the Rear Rail: Install the Rear Rail End Plate.
Install the rivets that secure the Rear Rail End Plate to the Rear Rail.
Install the Wing Bracket (Lower).
Install the Rear Panel Side Assembly.
Install the Butyl Foil patch as indicated.
Perform any necessary post-repair operations.