2025-08-22

Front Frame Rail Inner (Large Section)

Correction code: 10101008402 10101008502 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.

Parts List

Quantity Description Image / Notes
2 ASSEMBLY - FRONT RAIL INNER WITH BRACKET (Front Frame Rail Inner)
11 High Strength Structural Rivet, 6.5 mm

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 Shock Tower Support (Rear).
  2. Remove the Front Frame Rail Inner Reinforcement (Complete).
  3. Remove the original component.
    • Reference Line/Point
    • Cut Line A = 75 mm
  4. Remove the original component.
    • or Factory Spot Welds
  5. Cut the new Front Frame Rail Inner as indicated below to make the new component.
    • Reference Line/Point
    • Cut Line B = 75 mm
  6. Cut the new Front Frame Rail Inner as indicated below to create a reinforcement plate.
    • Reference Line/Point
    • Cut Line C = 35 mm D = 115 mm
  7. Prepare for installation.
    • or Installation Spot Welds
  8. Prepare for installation.
    • or Installation Spot Welds
  9. Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not add structural adhesive in the area circled in red (a Steel Plug Weld will be placed in that location in a later step).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    After securing the component, no structural adhesive may be within 25 mm. of any GMA weld location (structural adhesive within the GMA weld location can cause the weld to fail).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    When the panel is to be secured using GMA welding (plug welds), do not apply a bead of structural adhesive on top of the structural adhesive primer layer.
  10. Install the new component or components.
  11. 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.
  12. Install the Front Frame Rail Inner Reinforcement (Complete).
  13. Install the Shock Tower Support (Rear).
  14. Install the Front Trunk Bracket.
  15. Install the Front Subframe Mount (Inner).
  16. Install the fasteners as indicated.
  17. Install the fasteners as indicated.
  18. Install the fasteners as indicated.
  19. Perform GMA welding.
    • or Steel Plug 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
    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.
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
  20. Perform any necessary post-repair operations.