Front Frame Rail Inner (Large Front Section)

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 Front Frame Rail Inner (Large Front Section)

Parts List

Quantity Part Number Description Image / Notes

2 1080461-S0-A (LH) Front Frame Rail Inner
1080462-S0-A (RH)

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One Front Frame Rail Inner is needed for
replacement and one is needed to make a
backing plate.

1 1073811-S0-A (LH) Front Inner Front Subframe Mount

1073812-S0-A (RH)

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 Front Frame Rail Inner (Large Front Section)

Parts List

Quantity Part Number Description Image / Notes

1 — 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.

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1 — Corrosion-Resistant Epoxy Primer Source locally; not available from Tesla.

These part numbers were current at the time of publication. Use the revisions listed or later, unless otherwise specified in the
Parts Manual.

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 Front Frame Rail Inner (Large Front Section)

Repair Information

Repair Information Warnings and Cautions Special Tools

If the damage does not extend beyond WARNING: Wear the appropriate The special tools listed below are
the cut line specified in the "Removal" personal protective equipment required to perform this procedure:
section of the Front Frame Rail Inner (PPE) when performing this
(Small Front Section) procedure, procedure. • Resistance Spot Welder
discontinue this procedure and perform Use only an approved resistance spot
that procedure. CAUTION: This procedure involves
only steel components. Use the welder. Refer to BR-16-92-007,
This procedure is for the left-hand appropriate tools to avoid cross- "Approved Welders" for a list of
component; the procedure is identical for contamination. current approved resistance spot

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the right-hand component. welders.
• GMA welder
The items listed in the "Prerequisites"
section of this document include only the Use only an approved GMA welder.
last structural component that needs to Refer to BR-16-92-007, "Approved
be removed before starting the repair Welders" for a list of current approved
and any other prerequisites that are not GMA welders.
obvious. Refer to the estimating system • Frame bench
being used for a complete list of the The vehicle must be properly mounted
prerequisites that must be performed on an approved frame bench to
before starting the repair. replace this component. Refer to
BR-16-92-006, "Approved Frame
Bench Systems" for a list of current
approved bench repair systems.

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 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.

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NOTE: Before disconnecting the 12V power supply, make sure that the
driver’s door window is fully open. Failure to lower the driver's door
window before disconnecting the 12V power supply could result in
vehicle lockout.

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 Front Frame Rail Inner (Large Front Section)

Prerequisites

2
Remove the Front Shock Tower.

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3
Remove the Front Frame Rail Inner Reinforcement (Complete).

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 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

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Section) procedure, discontinue this procedure and perform that
procedure.

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 Front Frame Rail Inner (Large Front Section)

Removal

1
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.

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2
Remove the original section of the Front Frame Rail Inner.

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 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.
Cut Line

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B
Cut the new component on the cut line marked in the previous
substep.

NOTE: Leave 2 - 3 mm (3/32 - 1/8 in) of extra material to be

trimmed at a later step.

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 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.

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 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

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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.

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 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).

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NOTE: Cut around the indentation shown in the second image.

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 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).

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D
Put the reinforcement plate sections into position. If necessary, trim
them to fit.

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 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).

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E
Remove the reinforcement plate sections.

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 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.

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G
Clean the sections of the reinforcement plate 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.

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 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.

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 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.

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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.

NOTE: Do not fully weld the reinforcement plate sections together

while the plate is on the vehicle.

J
Remove the reinforcement plate sections.

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 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.

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WARNING: To maintain vehicle crash integrity, use only Bohler Union
X96 welding wire and an approved GMA welder to perform steel
GMA welding on high-strength steel and ultra high-strength steel
components.

L
Use a grinding tool to grind down the welds.

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 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.

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B
Mark the installation spot weld locations.
Installation Spot Weld (x25)

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 Front Frame Rail Inner (Large Front Section)

Replacement

3
Prepare for installation (continued).

B
Mark the installation spot weld locations (continued).

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C
Mark the surface preparation boundary lines on the original Front
Frame Rail Inner and the new Front Frame Rail Inner section.

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 Front Frame Rail Inner (Large Front Section)

Replacement

3
Prepare for installation (continued).

D
Remove the reinforcement plate.

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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

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 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.

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B
Mark the installation spot weld locations on the new section, the
reinforcement plate, and the vehicle.
Installation Spot Weld

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 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).

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 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).

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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.

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 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

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air dry can compromise the adhesive bond.

5
Apply structural adhesive.

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.

NOTE: Assembly must be performed while the primer layer is still

wet. The drying time of the adhesive varies depending on
temperature and humidity.

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 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).

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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.

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 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.

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B
Wipe off any excess adhesive.

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 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

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met Tesla’s requirements for welding training are authorized to weld
structural components on Tesla vehicles.

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: Use only insulated clamps within 200 mm (8 in) of

resistance spot weld locations. Do not perform resistance spot
welding when there is an uninsulated clamp within 200 mm (8 in) of
the spot weld location.

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 Front Frame Rail Inner (Large Front Section)

Replacement

6
Install the new section (continued).

C
Perform resistance spot welding (continued).

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 Front Frame Rail Inner (Large Front Section)

Replacement

7
Install the new Front Inner Front Subframe Bracket.

A
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.

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B
Mark the surface preparation boundary lines and installation spot
weld locations.
Installation Spot Weld (x4)

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 Front Frame Rail Inner (Large Front Section)

Replacement

7
Install the new Front Inner Front Subframe Bracket (continued).

C
Remove the new bracket.

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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.

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 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.

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F
Clean all the bond paths and weld areas on the new bracket and on
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.

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 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.

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H
While the primer layer is still wet, apply a bead of structural
adhesive on top of the primer layer on the vehicle.

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 Front Frame Rail Inner (Large Front Section)

Replacement

7
Install the new Front Inner Front Subframe Bracket (continued).

I
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.

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J
Wipe off any excess adhesive.

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 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

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met Tesla’s requirements for welding training are authorized to weld
structural components on Tesla vehicles.

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: Use only insulated clamps within 200 mm (8 in) of

resistance spot weld locations. Do not perform resistance spot
welding when there is an uninsulated clamp within 200 mm (8 in) of
the spot weld location.

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 Front Frame Rail Inner (Large Front Section)

Replacement

8
Remove any discoloration from the weld areas.

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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.

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 Front Frame Rail Inner (Large Front Section)

Replacement

10
Prime any bare metal with a suitable corrosion-resistant epoxy primer.

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11
Install a new Frunk Bracket.

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 Front Frame Rail Inner (Large Front Section)

Replacement

12
Install the new Front Frame Rail Inner Reinforcement (Complete).

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13
Install the new Front Shock Tower.

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