Cast Front Under Body Repair Guidelines

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

The images below show the cast Front Under Body from different angles, and contain highlighted areas. Compare the damaged area of the vehicle's Front 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 component can be repaired.


Front Under Body – Top View	Front Under Body – Bottom View
Front Under Body – Left Side View	Front Under Body – Right Side View
Front Under Body – Front Left Angled View	Front Under Body – Front Right Angled
Front Under Body – Rear Left Angled View	Front Under Body – Rear Right Angled

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 that are partially broken or cracked can be repaired by welding. Bent tabs can be straightened using cold methods. Note Do not use heat methods to straighten tabs. Scrapes or gouges on an edge that are less than 5 mm deep can be blended until smooth (not required).
Green areas:	Welding damage up to 50 mm is allowed. For damage more than 50 mm in length, contact Tesla Collision Repair for assistance 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. Scrapes or gouges on an edge that are less than 5 mm deep can be blended until smooth (not required). 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. 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. Scrapes or gouges on an edge that are less than 5 mm deep can be blended until smooth (not required).
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. 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. Scrapes or gouges on an edge that are less than 5 mm deep can be blended until smooth (not required).
Red areas:	None; if the Front 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. Note Scrapes or gouges on an edge that are less than 5 mm deep can be blended until smooth (not required). Warning Welding is not allowed in this area.

Discontinuities

The Cast Front Under Body may have discontinuities in the highlighted area. Discontinuities in these areas have no effect on structural integrity, and do not require repair.

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 tables (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.

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.