Front Frame Rail Outer (Complete) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Parts List Quantity Part Number 1 1103447-S0-A (LH) 1103448-S0-A (RH) Description Image / Notes Front Frame Rail Outer The Front Frame Rail Outer is listed in the Parts Manual as the "Front Rail Outer Assembly". 25 rivets needed; order 30 rivets 1454538-00-A High Strength Structural Rivet, 6.5 mm All rivets come in packages of 10; order all rivets in multiples of 10. 1 rivet needed; order 10 rivets 1069327-00-A Structural Countersunk Rivet, 6.
Front Frame Rail Outer (Complete) Repair Information Repair Information This procedure is for the left-hand component; the procedure is identical for the right-hand component. The items listed in the "Prerequisites" section of this document include only the last structural component that needs to be removed before starting the repair and any other prerequisites that are not obvious.
Front Frame Rail Outer (Complete) 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 Outer (Complete) Prerequisites 2 Remove the Torque Box Cover Assembly. 3 Remove the Shotgun Shear Wall. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Removal 1 Remove the original component. A Mark cut lines to prepare to cut away the bulk of the original component. Cut Line TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Removal 1 Remove the original component (continued). B Cut away the bulk of the original component. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Removal 1 Remove the original component (continued). C Use a drill with a spot weld bit to drill out the factory spot welds. Use a belt sander to sand down any factory spot welds that cannot be reached with a drill. Factory Spot Weld NOTE: The areas highlighted in yellow indicate multiple factory spot welds. NOTE: Factory spot weld locations shown are approximate. Exact spot weld locations and number vary from vehicle to vehicle.
Front Frame Rail Outer (Complete) Removal 1 Remove the original component (continued). C Use a drill with a spot weld bit to drill out the factory spot welds. Use a belt sander to sand down any factory spot welds that cannot be reached with a drill (continued). D Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the remaining pieces of the original component. WARNING: Do not heat any adhesive joints of components that are not being removed.
Front Frame Rail Outer (Complete) Removal 1 Remove the original component (continued). D Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the remaining pieces of the original component (continued). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Removal 2 Use a disc sander with a medium-abrasive surface conditioning disc to remove any remaining materials from the bond paths. Use a belt sander with a medium-abrasive belt for any areas that cannot be reached with a disc sander. Vacuum any adhesive dust. WARNING: Remove the epoxy adhesive in a well-ventilated area. Wear suitable personal protective equipment. 3 Remove any foam.
Front Frame Rail Outer (Complete) Replacement 1 Prepare for installation. A Put the new component into position and clamp it into place. B Align and temporarily secure the new component to the frame bench jig points. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Replacement 1 Prepare for installation (continued). C Mark the fastener locations on the new component. Structural Countersunk Rivet, 6.5 mm (x1) High Strength Structural Rivet, 6.5 mm (x25) Installation Spot Weld NOTE: Make sure the brake pedal is moved out of the way.
Front Frame Rail Outer (Complete) Replacement 1 Prepare for installation (continued). D Use a drill with a 6.7 mm (17/64 in) bit to drill holes for structural rivets and a structural countersunk rivet. CAUTION: Drill holes for countersunk rivets far enough away from the corners and any other obstructions to provide enough clearance (approximately 18 mm or 11/16 in) for the Microstop countersink cage assembly.
Front Frame Rail Outer (Complete) Replacement 1 Prepare for installation (continued). F Mark the surface preparation boundary lines on the new component and on the vehicle. G Remove the new component. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Replacement 1 Prepare for installation (continued). H Mark the bond path areas on the new component and the vehicle. These areas will be prepared for bonding in the next step. Steel-to-Steel Bond Path TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Replacement 2 Prepare the surfaces. A Use a red Scotch-Brite pad or equivalent to scuff the e-coat on the new component and on the vehicle in the bond path areas. B Mark the installation spot weld locations on the new component and on the vehicle. Installation Spot Weld TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Replacement 2 Prepare the surfaces (continued). C Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat on the new component and on the vehicle in the weld areas. Use a belt sander with a medium-abrasive belt for any areas that cannot be reached with a disc sander. WARNING: Remove the e-coat in a well-ventilated area. Wear suitable personal protective equipment.
Front Frame Rail Outer (Complete) Replacement 3 Apply structural adhesive. A Spread a thin coating of structural adhesive as a primer layer on the bond paths on the vehicle and the new component. NOTE: Assembly must be performed while the primer layer is still wet. The drying time of the adhesive varies depending on temperature and humidity. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Replacement 3 4 Apply structural adhesive (continued). B While the primer layer is still wet, apply a bead of structural adhesive on top of the primer layer on the vehicle. Install the new component. A Put the new component into position and clamp it into place. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Replacement 4 Install the new component (continued). B Align and temporarily secure the new component to the frame bench jig points. C Insert the structural rivets and the structural countersunk rivet. Structural Countersunk Rivet, 6.5 mm (x1) High Strength Structural Rivet, 6.5 mm (x25) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Replacement 4 Install the new component (continued). C Insert the structural rivets and the structural countersunk rivet (continued). D Install the structural rivets and the structural countersunk rivet. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Replacement 4 Install the new component (continued). D Install the structural rivets and the structural countersunk rivet (continued). E Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Replacement 4 Install the new component (continued). F Temporarily install an M6 bolt through the existing hole on the top of the Front Frame Rail. NOTE: The M6 bolt was removed with the Shotgun Shear Wall. A new bolt is not needed for this step. NOTE: Do not torque the bolt at this time, as it will be removed when installing the Shotgun Shear Wall. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Replacement 4 Install the new component (continued). G Perform resistance spot welding. Installation Spot Weld (x22) 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 Outer (Complete) Replacement 4 Install the new component (continued). G Perform resistance spot welding (continued). H Remove any discoloration from the weld areas. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Replacement 4 Install the new component (continued). I 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 Outer (Complete) Replacement 6 Prime any bare metal with a suitable corrosion-resistant epoxy primer. 7 Install the new Shotgun Shear Wall. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Front Frame Rail Outer (Complete) Replacement 8 Install the new Torque Box Cover Assembly. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
