Shotgun Outer TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Parts List Quantity 1 Part Number Description Image / Notes 1073755-S0-A (LH) Shotgun Outer 1073756-S0-A (RH) 3 rivets needed; order 10 rivets. 1063943-00-A 1 — Structural Bulb Rivet, 6.5 mm Weld-Through Primer All rivets come in packages of 10; order all rivets in multiples of 10. CAUTION: Only use zinc weld-through primers. Other primers might cause corrosion and compromise the integrity of the repair. Source locally; not available from Tesla.
Shotgun Outer Repair Information Repair Information This procedure shows the left-hand component being removed and the righthand component being installed. Warnings and Cautions WARNING: Wear the appropriate personal protective equipment (PPE) when performing this procedure. CAUTION: This procedure involves only steel components. Use the appropriate tools to avoid crosscontamination. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Prerequisites 1 Disconnect 12V and high voltage power. WARNING: If the 12V power supply is disconnected, do not attempt to open any doors with the door glass in a closed position. Attempting to open a door when the 12V power supply is disconnected could result in door glass shatter. NOTE: Before disconnecting the 12V power supply, make sure that the driver’s door window is fully open.
Shotgun Outer Prerequisites 2 Remove the items listed below. Refer to the applicable Service Manual procedure. • Front Door TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Removal 1 Remove the original component. A Remove the bolts, but do not discard them. Bolt, hex-head (x3) NOTE: These bolts are installed in a later substep. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Removal 1 Remove the original component (continued). B Identify the factory spot welds. Factory Spot Weld Areas NOTE: Factory spot weld locations shown are approximate. Exact spot weld locations and number vary from vehicle to vehicle. NOTE: The areas highlighted in yellow indicate multiple factory spot welds. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer 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. D Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the original component. WARNING: Do not heat any adhesive joints of components that are not being removed.
Shotgun Outer 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 original component (continued). E Remove the original component. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer 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. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 1 Prepare for installation. A Put the new component into position and clamp it into place. B Insert the 3 bolts that were removed in an earlier substep, but do not torque them fully at this time. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 1 Prepare for installation (continued). C Use a tram gauge to measure the distance between the two Shotgun Outers. Measure from the manufacturing location holes. NOTE: The factory distance between the two Shotgun Outers is 1090 mm (43 in). D Mark the fastener locations on the new component. Installation Spot Weld Structural Bulb Rivet, 6.5 mm (x3) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 1 Prepare for installation (continued). E Use a drill with a 6.8 mm (17/64 in) bit to drill holes for structural bulb rivets. Structural Bulb Rivet, 6.5 mm (x3) F Mark the new component in the areas that need to have e-coat removed. Steel-to-Steel Bond Path TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 1 Prepare for installation (continued). F Mark the new component in the areas that need to have e-coat removed (continued). G Remove the new component. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 2 Prepare the surfaces. A 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 bond path areas and 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.
Shotgun Outer Replacement 2 Prepare the surfaces (continued). C Identify the adhesive bond path and spot weld areas. Structural Adhesive Installation Spot Weld NOTE: Some areas will be both glued and spot welded in later substeps. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 2 Prepare the surfaces (continued). D Use tape to mask off the structural adhesive bond path areas on the new component and on the vehicle. E Apply weld-through primer to the appropriate installation spot weld areas of the new component and the vehicle. CAUTION: Only use zinc weld-through primers. Other primers might cause corrosion and compromise the integrity of the repair. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 2 Prepare the surfaces (continued). F Remove the tape. G Clean the areas that were taped in the previous substeps with isopropyl alcohol (IPA). TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 3 Apply structural adhesive. A Spread a thin coating of structural adhesive as a primer layer on the abraded steel bond paths on the vehicle and the new Shotgun Outer. 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. NOTE: Assembly must be performed while the primer layer is still wet.
Shotgun Outer 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. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 4 Install the new component (continued). B Install the original bolts. Torque the bolts to 35 Nm (26 ft. lb.). Bolt, hex-head (x3) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 4 Install the new component (continued). C Use a tram gauge to measure the distance between the two Shotgun Outers. Measure from the manufacturing location holes. NOTE: The factory distance between the two Shotgun Outers is 1090 mm (43 in). D Clamp the new component into place. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 4 Install the new component (continued). E Install the structural bulb rivets. F Wipe off any excess adhesive. Structural Bulb Rivet, 6.5 mm (x3) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 4 Install the new component (continued). G Perform resistance spot welding. Installation Spot Weld TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Shotgun Outer Replacement 4 Install the new component (continued). H 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. I Remove any discoloration from the weld areas.
Shotgun Outer Replacement 4 Install the new component (continued). J Prime any bare metal with a suitable corrosion-resistant primer. K After refinishing, use a wand of suitable length to apply corrosionproofing material on the inside of the enclosed area to prevent corrosion. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
