Front Frame Rail Inner (Large Front Section) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Parts List Quantity 2 Part Number Description Image / Notes 1080461-S0-A (LH) Front Frame Rail Inner 1080462-S0-A (RH) One Front Frame Rail Inner is needed for replacement and one is needed to make a backing plate. 1 1073811-S0-A (LH) 1073812-S0-A (RH) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Parts List Quantity Part Number 1 — Description Image / Notes Structural Adhesive WARNING: Use only Tesla-approved structural adhesive; refer to BR-15-92-008, "Approved Structural Adhesive and Urethane Sealants" for a list of current approved structural adhesives. Refer to BR-17-92-002, "Obtaining Adhesives, Coolant, and Other Chemicals" for information on how to obtain approved structural adhesive.
Front Frame Rail Inner (Large Front Section) Repair Information Repair Information If the damage does not extend beyond the cut line specified in the "Removal" section of the Front Frame Rail Inner (Small Front Section) procedure, discontinue this procedure and perform that procedure. This procedure is for the left-hand component; the procedure is identical for the right-hand component. Warnings and Cautions WARNING: Wear the appropriate personal protective equipment (PPE) when performing this procedure.
Front Frame Rail Inner (Large Front Section) Prerequisites 1 Disconnect 12V and high voltage power (refer to the appropriate section in BR-17-17-004, "Disconnecting 12V and High Voltage Power on Model 3"). WARNING: Before disconnecting the 12V power supply, make sure that all windows are at least slightly open. Attempting to open a door with a fully-closed window when the 12V power supply is disconnected could result in door glass shatter.
Front Frame Rail Inner (Large Front Section) Prerequisites 2 Remove the Front Shock Tower. 3 Remove the Front Frame Rail Inner Reinforcement (Complete). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Removal 1 Remove the original component. A Mark a cut line 75 mm (3-15/16 in) from the middle of the location hole on the original Front Frame Rail Inner. Cut Line NOTE: If the damage does not extend beyond the cut line specified in the "Removal" section of the Front Frame Rail Inner (Small Front Section) procedure, discontinue this procedure and perform that procedure.
Front Frame Rail Inner (Large Front Section) Removal 1 2 Remove the original component (continued). B Cut the component on the cut line marked in the previous substep. CAUTION: Do not damage the surrounding components. Remove the original section of the Front Frame Rail Inner. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 1 Prepare the new Front Frame Rail Inner section for installation. A Mark a cut line 75 mm (3-15/16 in) from the middle of the location hole shown on the first new Front Frame Rail Inner. B Cut the new component on the cut line marked in the previous substep. Cut Line NOTE: Leave 2 - 3 mm (3/32 - 1/8 in) of extra material to be trimmed at a later step.
Front Frame Rail Inner (Large Front Section) Replacement 1 Prepare the new Front Frame Rail Inner section for installation (continued). C Put the new section into position and align it to the frame bench jig points. NOTE: If necessary, trim the new section to fit. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 2 Prepare the reinforcement plate. A On the second Front Frame Rail Inner, mark cut lines 35 mm (1-3/8 in) and 115 mm (4-1/2 in) from the middle of the location hole shown. Cut Line B Cut the second Front Frame Rail Inner on the cut lines marked in the previous substep to create an 80 mm (3-1/8 in) reinforcement plate. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 2 Prepare the reinforcement plate (continued). C Cut the reinforcement plate on the cut lines shown. Cut Line NOTE: Discard the outer sections and save the 3 inner sections (highlighted in yellow). NOTE: Cut around the indentation shown in the second image. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 2 Prepare the reinforcement plate (continued). C Cut the reinforcement plate on the cut lines shown (continued). D Put the reinforcement plate sections into position. If necessary, trim them to fit. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 2 Prepare the reinforcement plate (continued). D Put the reinforcement plate sections into position. If necessary, trim them to fit (continued). E Remove the reinforcement plate sections. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 2 Prepare the reinforcement plate (continued). F Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat on the reinforcement plate sections in the areas where the sections meet. WARNING: Remove the e-coat in a well-ventilated area. Wear suitable personal protective equipment. G Clean the sections of the reinforcement plate with isopropyl alcohol (IPA).
Front Frame Rail Inner (Large Front Section) Replacement 2 Prepare the reinforcement plate (continued). H Put the reinforcement plate sections into position. Clamp them into place. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 2 Prepare the reinforcement plate (continued). I Tack weld the reinforcement plate sections together. 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 successfully met Tesla’s requirements for welding training are authorized to weld structural components on Tesla vehicles.
Front Frame Rail Inner (Large Front Section) Replacement 2 Prepare the reinforcement plate (continued). K Weld the reinforcement plate sections together. 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 successfully met Tesla’s requirements for welding training are authorized to weld structural components on Tesla vehicles.
Front Frame Rail Inner (Large Front Section) Replacement 3 Prepare for installation. A Put the reinforcement plate into position. If necessary, trim it to fit. B Mark the installation spot weld locations. Installation Spot Weld (x25) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 3 Prepare for installation (continued). B Mark the installation spot weld locations (continued). C Mark the surface preparation boundary lines on the original Front Frame Rail Inner and the new Front Frame Rail Inner section. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 3 Prepare for installation (continued). D Remove the reinforcement plate. E Mark the bond path areas on the new Front Frame Rail Inner section, the inside surface of the reinforcement plate, and the vehicle. Steel-to-Steel Bond Path TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 4 Prepare the surfaces. A Use a red Scotch-Brite pad or equivalent to scuff the e-coat on the new section, the reinforcement plate, and the vehicle in the bond path areas. B Mark the installation spot weld locations on the new section, the reinforcement plate, and the vehicle. Installation Spot Weld TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 4 Prepare the surfaces (continued). B Mark the installation spot weld locations on the new section, the reinforcement plate, and the vehicle (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 4 Prepare the surfaces (continued). B Mark the installation spot weld locations on the new section, the reinforcement plate, and the vehicle (continued). C Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat on the new section, the reinforcement plate, and the vehicle in the weld areas. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 4 Prepare the surfaces (continued). D Clean all the bond path areas and weld areas on the new section, the reinforcement plate, and the vehicle with isopropyl alcohol (IPA). WARNING: Wipe off the remaining isopropyl alcohol with a clean, dry towel immediately after application. Do not let the remaining isopropyl alcohol air dry. Allowing the remaining isopropyl alcohol to air dry can compromise the adhesive bond. 5 Apply structural adhesive.
Front Frame Rail Inner (Large Front Section) Replacement 5 Apply structural adhesive (continued). A Spread a thin coating of structural adhesive as a primer layer on the bond paths on the new section, the reinforcement plate, and the vehicle (continued). B While the primer layer is still wet, apply a bead of structural adhesive on top of the primer layer on the new section and the vehicle. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 6 Install the new section. A Put the reinforcement plate into position and clamp it into place. B Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 6 Install the new section (continued). C Perform resistance spot welding. Installation Spot Weld (x25) 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 successfully met Tesla’s requirements for welding training are authorized to weld structural components on Tesla vehicles.
Front Frame Rail Inner (Large Front Section) Replacement 6 Install the new section (continued). C Perform resistance spot welding (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 7 Install the new Front Inner Front Subframe Bracket. A B Put the new bracket into position and clamp it into place. NOTE: Align the holes in the bracket with the holes in the Front Frame Rail Inner. Mark the surface preparation boundary lines and installation spot weld locations. Installation Spot Weld (x4) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 7 Install the new Front Inner Front Subframe Bracket (continued). C Remove the new bracket. D Use a red Scotch-Brite pad or equivalent to scuff the e-coat on the new bracket and on the vehicle in the bond path areas. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 7 Install the new Front Inner Front Subframe Bracket (continued). E Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat on the new bracket and on the vehicle in the weld areas. NOTE: Use a belt sander with a medium-abrasive belt for any areas that cannot be reached with a disc sander. F Clean all the bond paths and weld areas on the new bracket and on the vehicle with isopropyl alcohol (IPA).
Front Frame Rail Inner (Large Front Section) Replacement 7 Install the new Front Inner Front Subframe Bracket (continued). G Spread a thin coating of structural adhesive as a primer layer on the bond paths on the new bracket and the vehicle. H While the primer layer is still wet, apply a bead of structural adhesive on top of the primer layer on the vehicle. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 7 Install the new Front Inner Front Subframe Bracket (continued). I J Put the new bracket into position and clamp it into place. NOTE: Align the holes in the bracket with the holes in the Front Frame Rail Inner. Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 7 Install the new Front Inner Front Subframe Bracket (continued). K Perform resistance spot welding. Installation Spot Weld (x4) 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 successfully met Tesla’s requirements for welding training are authorized to weld structural components on Tesla vehicles.
Front Frame Rail Inner (Large Front Section) Replacement 8 Remove any discoloration from the weld areas. 9 Bake the structural adhesive so that the bonded panels reach a temperature of 60°C–80°C (140°F–176°F) for at least 30 minutes to achieve full strength. WARNING: Do not allow the High Voltage Battery to reach a temperature above 74°C (165°F). Heating the High Voltage Battery above 74°C (165°F) for an extended period could result in injury to personnel and/or damage to the battery.
Front Frame Rail Inner (Large Front Section) Replacement 10 Prime any bare metal with a suitable corrosion-resistant epoxy primer. 11 Install a new Frunk Bracket. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Inner (Large Front Section) Replacement 12 Install the new Front Frame Rail Inner Reinforcement (Complete). 13 Install the new Front Shock Tower. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
