04/12/2024 18:18:43

Rear Under Body (Section)

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.
The Rear Under Body is a single component, and can be replaced as a single repair, as described in the Rear Under Body (Complete) procedure. Alternatively, instead of replacing the complete Mast Assembly, the LH or RH side of the Rear Under Body can be replaced using a Rear Under Body Half Section service part and the top and bottom reinforcement plates described in the Parts List, and the instructions in the Repair Procedure.

Parts List


Quantity	Description	Image / Notes
1	ASSEMBLY - REAR UNDER BODY HALF SECTION (Rear Under Body Half Section)
1	TOP STAMPING
1	BOTTOM STAMPING
2	PLUG	Tesla part number 1870761-00.
17	High Strength Structural Rivet, 6.5 mm
3	Bolt BLT,HHL,M10x33	Tesla part number 1851387-00.

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

On the original component, verify the location of the center point for the rear-most access hole.
The center point for the rear-most access hole should be located 155 mm to the rear of the indicated hole (measurement A).
Note
If the center point marked on the component is 150 mm, move the center point 5 mm to the rear of the marked center point (measurement B).
Reference Line/Point
- A = 155 mm.
- B = 5 mm.
On the original component, cut the rear access holes.
Cut Line
Note
Use a 1 1/8 inch (29 mm.) carbide-tipped hole saw to create the holes.
Separate the Rear Under Body Sections.
Cut next to the raised cut line on the damaged side of the component.
Cut Line
Note
If the Rear Under Body is damaged on both sides of the raised cut line, sectioninng is not allowed and the entire component must be replaced as described in the Rear Under Body (Complete) procedure.
Remove the original component.
or Factory Spot Welds
or Factory SPRs

or Bolts
Bulk cut and remove the Rear Under Body casting.
Cut the Rear Under Body near the C-Pillar Inner area as shown, then remove the cut portion of the original component. (Removing casting material will assist with the heating and separating process.)
Note
To prevent damage to the C-Pillar Inner, when cutting near the inboard side of the C-Pillar Inner, cut only in the area shown in yellow (do not cut in the area shown in red).
Cut Line
Remove the remaining portion of the original component.
Use heat and separation methods, then grind as necessary to remove the remaining casting material (shown in red) near the C-Pillar Inner area.
Note
Use caution to make sure that the C-Pillar Inner is not damaged when removing the remaining portion of the original Rear Under Body casting.
Prepare for installation.
Trim the remaining portion of the existing component on the vehicle to fit.
Note
The maximum gap between new and existing components is 3 mm.
Note
A red X indicates a location where a factory-installed fastener is not being replaced.
or High Strength Structural Rivets, 6.5 mm
or Bolts
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 90 Nm.
Note
Fill any gaps with structural adhesive.
Trim the Rear Rocker Step Reinforcement to allow clearance for the plug that covers the rear access hole.
Cut Line

Reference Line/Point
- C = 7 mm.
- D = 32 mm.
Install the plugs to cover the access holes.

Note
Apply seam sealer to the bottom side of each plug before installation, and remove any visible seam sealer around the outside edge of the plug after installation.

Note
Remove any visible seam sealer from around the access hole plugs that would be under the foam gasket of the Rear Rocker Step Reinforcement.
Install the Tailgate Tower.
Perform any necessary post-repair operations.