Cast Rear Under Body (1–Piece) Repair Guidelines

Explains how to determine if the cast Rear Under Body can be repaired or if replacement is required.

The criteria to determine if a 1-piece cast Rear Under Body component is repairable or if the Rear Under Body must be replaced are based on both the severity and the location of the damage. Use the images and information below to determine if the Rear Under Body component may be repaired or if replacement is required.

The images below show several different sides of the cast Rear Under Body, and contain highlighted areas. Compare the damaged area of the vehicle's cast Rear Under Body 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 Rear Under Body can be repaired.

Note

If damage spans repair areas, contact Tesla Collision Repair for assistance before starting the repair. Do not repair damage that crosses repair area boundaries without prior approval from Tesla Collision Repair.


1-Piece Rear Under Body – Top View	1-Piece Rear Under Body – Bottom View
1-Piece Rear Under Body – Side View	1-Piece Rear Under Body – Angled View

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

Table 1. Allowed Repairs
Area Color	Allowed Repairs
Blue areas:	Tabs that are broken off entirely can be welded back into place. Tabs or sections that are partially broken or cracked can be repaired by welding. Bent tabs or sections can be straightened using cold methods. Note Do not use heat methods to straighten tabs or sections. On the motor bay cover only: Butyl patches and sealant can be used to address discontinuities in the motor bay cover.
Green areas:	Welding damage up to 50 mm is allowed. For damage more than 50 mm in length, contact Tesla Collision Repair for assistance. A broken stud may be welded on or replaced with a double-ended. See Replacing a Damaged Stud for more information. Bent webbing sections may be straightened using cold methods. Note Do not use heat methods to straighten webbing sections. Note After repair, bent webbing sections should be restored to within 1.5 mm of their original position. On the motor bay cover only: Butyl patches and sealant can be used to address discontinuities in the motor bay cover. Note Contact Tesla Collision Repair if there are concerns about the number or width of discontinuities in the component.
Yellow areas:	Welding damage up to 30 mm is allowed (a reinforcement plate is not required). Welding damage between 30 mm and 50 mm in length is allowed, but reinforcement plates (Tesla part number 1076938-E0-B) must also be installed. See Installing a Reinforcement Plate for more information. For damage more than 50 mm in length, contact Tesla Collision Repair for assistance. A broken stud may be welded on or replaced with a double-ended stud. See Replacing a Damaged Stud for more information. Bent webbing sections may be straightened using cold methods. Note Do not use heat methods to straighten webbing sections. Note After repair, bent webbing sections should be restored to within 1.5 mm of their original position.
Orange areas:	Welding a crack up to 30 mm is allowed, but a reinforcement plate (Tesla part number 1076938-E0-B) must also be installed. See Installing a Reinforcement Plate for more information. For damage more than 30 mm in length, contact Tesla Collision Repair for assistance. A broken stud may be welded on or replaced with a double-ended stud. See Replacing a Damaged Stud for more information. Bent webbing sections may be straightened using cold methods. Note Do not use heat methods to straighten webbing sections. Note After repair, bent webbing sections should be restored to within 1.5 mm of their original position.
Red areas:	None; if the Rear Under Body is damaged in these areas, contact Tesla Collision Repair for assistance. Note A broken stud may replaced with a double ended stud. See Replacing a Damaged Stud for more information. Warning Welding is not allowed in this area.

Installing a Reinforcement Plate

Reinforcement plates may be installed on the Rear Under Body only at the direction of the Tesla Collision Repair Support Team, or as specified in the Allowed Repairs tables (above). Reinforcement plates on the Rear Under Body are installed as follows:

Note

Reinforcement plates on the Rear Under Body are not installed by welding; Rear Under Body reinforcement plates are installed only with structural adhesive.

Straighten the area where the reinforcement plate will be installed using cold methods.
Note
Do not use heat methods to straighten webbing sections.
Cut a section of reinforcement plate to length.
Note
Reinforcement plates are placed on both sides of cracked or straightened webbing. Make sure that each reinforcement plate covers the maximum surface area around the repair area.
Trim and rework the reinforcement plate as necessary to snugly fit over the area to be reinforced, and allow for any adjoining panels.
Remove any contaminants from the mating surfaces on the repair area and the reinforcement plate by cleaning them with isopropyl alcohol (IPA) prior to applying structural adhesive.
Apply structural adhesive.
Fit the reinforcement plates into position and clamp them into place.
Wipe off excess structural adhesive.

Warning

Before performing any repair that requires fasteners to be installed through an installed reinforcement plate, contact Tesla Collision Repair for assistance. Because the reinforcement plate increases panel stack thickness, it may be necessary to change fasteners used in repairs performed after the reinforcement plate has been installed.

Replacing a Damaged Stud

A damaged or broken stud may be replaced using a double-ended stud (Tesla part number 1463292-00-C).

To replace a broken stud:

Grind down the damaged stud until it is flush with the surrounding material.
Use a center punch to mark the center of the remaining part of the stud (the location of the replacement stud).
Drill a 5.5 mm. hole that is 22 mm. deep in the replacement stud location.
Remove all debris from the drilled hole.
Insert the self-tapping double ended stud and torque it to 5 Nm.