Mast Assembly Repair Guidelines

Explains how to determine if the cast Mast Assembly can be repaired or if replacement is required.

The criteria to determine if a Mast Assembly component is repairable or if the component 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 Mast Assembly may be repaired or if replacement is required.

The images below show several different sides of the cast Mast Assembly, and contain highlighted areas. Compare the damaged area of the vehicle's Mast Assembly 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 Mast Assembly 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.


Mast Assembly – Top View	Mast Assembly – Bottom View
Mast Assembly – Inboard View	Mast Assembly – Outboard View
Mast Assembly – Angled Inboard View	Mast Assembly – Angled Outboard 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.
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. 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.
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. 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.

Installing a Reinforcement Plate

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

Note

Reinforcement plates are not installed by welding; 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.