2024-11-05

Front Frame Rail Assembly

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	ASSEMBLY - FRONT RAIL (Front Frame Rail Assembly)
1	PNL, LONGITUDINAL UPPER (Longitudinal Upper)
1	BUTYL FOIL PATCH 300X150x2MM (Butyl Foil Patch)	Tesla part number 1004969-00-A.
42	High Strength Structural Rivet, 6.5 mm
28	Structural Bulb Rivet, 6.5 mm
10	Countersunk Rivet, 4.8 mm Short
2	Countersunk Rivet, 4.8 mm Long
1	Rivet, 4.8 mm
1	Flow Form Rivet S38
4	Bolt , M8X16 - M6 HF -[10.9] -ZNAL -HD -OD14.9	Tesla part number 1011818-00-A.
4	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

Remove the Shotgun Outer.
Remove the Dash Crossmember.
Remove the Front Subframe Support.
Remove the original component.
- or Factory Spot Welds
Remove the original component.
- or Factory Spot Welds
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
Remove the original component.
- or Factory Spot Welds
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
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.
Prepare to install the Longitudinal Upper on the Front Frame Rail Assembly.
- or High Strength Structural Rivets, 6.5 mm
- or Rivets, 4.8 mm
- or Installation Spot Welds
Prepare to install the Longitudinal Upper on the Front Frame Rail Assembly.
- Reference Line/Point
- or High Strength Structural Rivets, 6.5 mm A = 73 mm B = 63 mm
- or Rivets, 4.8 mm
- or Installation Spot Welds
Apply structural adhesive to the mating surfaces on the Front Frame Rail and the Longitudinal Upper.
Install the Longitudinal Upper on the Front Frame Rail.
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.
Prepare for installation.
- or High Strength Structural Rivets, 6.5 mm
- or Structural Bulb Rivets, 6.5 mm
Prepare for installation.
- Reference Line/Point
- or Structural Bulb Rivets, 6.5 mm
- or Bolts C = 10 mm D = 9 mm
Prepare for installation.
- or High Strength Structural Rivets, 6.5 mm
- or Structural Bulb Rivets, 6.5 mm
- or Flow Form Rivets, S38
- or Bolts
Prepare for installation.
- or High Strength Structural Rivets, 6.5 mm
- or Structural Bulb Rivets, 6.5 mm
Prepare for installation.
- or High Strength Structural Rivets, 6.5 mm
Prepare for installation.
- or High Strength Structural Rivets, 6.5 mm
- or Structural Bulb Rivets, 6.5 mm
Prepare for installation.
Note
A red X indicates a location where a factory-installed fastener is not being replaced.
Note
Each Countersunk Rivet in the highlighted area is installed slightly offset from the location where a drill through factory spot weld was removed.
Prepare for installation.
- or Structural Bulb 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 22 Nm.
Install the Front Subframe Support.
Install the Dash Crossmember.
Install the Shotgun Outer.
Cut the butyl foil patch as needed and cover the installed rivets as shown.
Perform any necessary post-repair operations.