2025-03-13

Rear Rail (Cast)

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.
Prepare for installation.
- Reference Line/Point
- Bolt, Torx-head A = 107 mm B = 37 mm C = 152 mm D = 34 mm
Note
Install inboard and outboard bolts installation.
Prepare for installation.
- Bolt, Torx-head
Prepare for installation.
- or High Strength Structural Rivets, 6.5 mm
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 does 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.