Toeboard Outer TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Toeboard Outer Parts List Quantity Part Number 1 1092173-S0-A (LH) 1092174-S0-A (RH) 17 rivets needed; order 20 rivets 1454538-00-A 1 — Description Image / Notes M3 ASY - TOEBOARD OUTER PNL (Toeboard Outer Panel) High Strength Structural Rivet, 6.5 mm All rivets come in packages of 10; order all rivets in multiples of 10. Structural Adhesive Refer to BR-17-92-002, "Obtaining Adhesives, Coolant, and Other Chemicals" for information on how to obtain approved structural adhesive.
Toeboard Outer Repair Information Repair Information This procedure is for the left-hand component; the procedure is identical for the right-hand component. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com. Warnings and Cautions WARNING: Wear the appropriate personal protective equipment (PPE) when performing this procedure.
Toeboard Outer 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.
Toeboard Outer Removal Remove the original component. 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. A Factory Spot Weld NOTE: Factory spot weld locations shown are approximate. Exact spot weld locations and number vary from vehicle to vehicle. B Use a drill with a spot weld bit to drill out the factory spot welds.
Toeboard Outer Removal Remove the original component (continued). Use a heat gun to heat the adhesive joints, and then use a hammer and chisel to remove the original component. C WARNING: Do not heat any adhesive joints of components that are not being removed. Heating adhesive joints weakens the adhesive bond and could compromise vehicle crash integrity. WARNING: Do not heat the adhesive joints above 100°C (212°F).
Toeboard Outer Replacement 1 Prepare for installation. A Put the new component into position and secure it in place. B Mark the fastener locations on the new component. High Strength Structural Rivet, 6.5 mm (x17) Steel Plug Weld (x7) WARNING: Use the measurements indicated for the outboard rivets to avoid interference with the Sill Insert. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Toeboard Outer Replacement 1 Prepare for installation (continued). C Drill 6.7 mm holes for structural rivets. High Strength Structural Rivet, 6.5 mm (x17) NOTE: Install a grip screw after drilling each hole to keep the panel aligned while drilling the remaining holes. D Mark boundary lines along all mating surfaces between the new component and the vehicle for surface preparation. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Toeboard Outer Replacement 1 Prepare for installation (continued). E Remove the new component. F Drill 8 mm holes for plug welds. Steel Plug Weld (x7) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Toeboard Outer Replacement 2 Prepare the surfaces. A Use a red Scotch-Brite pad or equivalent to scuff the e-coat on the mating surfaces of the new component and the vehicle. B Use a disc sander with a medium-abrasive surface conditioning disc to remove the e-coat from the mating surfaces and weld areas of the new component and the vehicle. 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.
Toeboard Outer Replacement 2 Prepare the surfaces (continued). C Clean all the mating surfaces of the new component or components 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. 3 Apply structural adhesive.
Toeboard 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 and secure it in place. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Toeboard Outer Replacement 4 Install the new component (continued). B Insert the structural rivets. C Install the structural rivets. High Strength Structural Rivet, 6.5 mm (x17) TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Toeboard Outer Replacement 4 Install the new component (continued). D Clamp all bonded areas that are not secured with a fastener. E Wipe off any excess adhesive. TESLA BODY REPAIR MANUAL For feedback on the accuracy of this document, email BodyRepair@tesla.com.
Toeboard Outer Replacement 4 Install the new component (continued). F 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. G Perform GMA welding.
Toeboard Outer Replacement 4 Install the new component (continued). G Perform GMA welding (continued). CAUTION: Do not weld on a Tesla vehicle with an energized high voltage or 12V system. Welding on a Tesla vehicle with an energized high voltage or 12V system might damage vehicle components. CAUTION: Grind the bottom surface of each weld flat to avoid contact with the top of the HV battery.
