Front Frame Rail Inner Reinforcement (Section)

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 Front Frame Rail Inner Reinforcement (Section)

Parts List

Quantity Part Number Description Image / Notes

1 1080477-S0-A (LH) Front Frame Rail Inner
1080478-S0-A (RH) Reinforcement

1 — Structural Adhesive WARNING: Use only Tesla-approved

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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.

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 Reinforcement (Section)

Repair Information

Repair Information Warnings and Cautions Special Tools

This procedure is for the right-hand WARNING: Wear the appropriate The special tools listed below are
component; the procedure is identical for personal protective equipment required to perform this procedure:
the left-hand component. (PPE) when performing this
procedure. • Resistance Spot Welder

CAUTION: This procedure involves Use only an approved resistance spot

only steel components. Use the welder. Refer to BR-16-92-007,
appropriate tools to avoid cross- "Approved Welders" for a list of
contamination. current approved resistance spot

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welders.
• GMA welder
Use only an approved GMA welder.
Refer to BR-16-92-007, "Approved
Welders" for a list of current approved
GMA welders.
• Frame bench
The vehicle must be properly mounted
on an approved frame bench to
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 Reinforcement (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 Reinforcement (Section)

Prerequisites

2
Remove the Front Frame Rail Outer (Section).

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 Front Frame Rail Inner Reinforcement (Section)

Removal

1
Remove a section of the original component.

A
Mark a cut line 115 mm (4-1/2 in) forward from the remaining piece
of the Front Frame Rail Outer section.
Cut Line
Reference Line/Point

NOTE: The Front Frame Rail Outer was cut at the reference line

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during removal of the Front Frame Rail Outer (section).

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 Front Frame Rail Inner Reinforcement (Section)

Removal

1
Remove a section of the original component (continued).

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

NOTE: Do not damage the Front Frame Rail Inner.

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C
Use a drill with a spot weld bit to drill out the factory spot welds.
Factory Spot Weld (x17)

NOTE: Factory spot weld locations shown are approximate. Exact

spot weld locations and number vary from vehicle to vehicle.

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 Front Frame Rail Inner Reinforcement (Section)

Removal

1
Remove a section of the original component (continued).

C
Use a drill with a spot weld bit to drill out the factory spot welds
(continued).

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D
Use a heat gun to heat the adhesive joints, and then use a hammer
and chisel to remove the section of the original Front Frame Rail
Inner Reinforcement.

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.

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 Front Frame Rail Inner Reinforcement (Section)

Removal

1
Remove a section of the original component (continued).

D
Use a heat gun to heat the adhesive joints, and then use a hammer
and chisel to remove the section of the original Front Frame Rail
Inner Reinforcement (continued).

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 Front Frame Rail Inner Reinforcement (Section)

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.

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 Front Frame Rail Inner Reinforcement (Section)

Replacement

1
Prepare for installation.

A
Mark a cut line 420 mm (16-1/2 in) from the front of the new Front
Frame Rail Inner Reinforcement.
Cut Line

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 Front Frame Rail Inner Reinforcement (Section)

Replacement

1
Prepare for installation (continued).

B
Cut the 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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C
Put the new section into position and clamp it into place.

TIP: Make sure all 4 holes in the new Front Frame Rail Inner
Reinforcement are aligned with the 4 holes in the existing Front
Frame Rail Inner.

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 Front Frame Rail Inner Reinforcement (Section)

Replacement

1
Prepare for installation (continued).

D
Mark the surface preparation boundary lines on the new section and
on the vehicle.

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E
Remove the new section.

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 Front Frame Rail Inner Reinforcement (Section)

Replacement

1
Prepare for installation (continued).

F
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

NOTE: Mark the bond path areas on the new section that
correspond to the bond paths shown on the vehicle.

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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.

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 Front Frame Rail Inner Reinforcement (Section)

Replacement

2
Prepare the surfaces (continued).

B
Mark the installation spot weld locations on the new section and on
the vehicle.
Installation Spot Weld (x12)

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 Front Frame Rail Inner Reinforcement (Section)

Replacement

2
Prepare the surfaces (continued).

B
Mark the installation spot weld locations on the new section and on
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 and 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.

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 Front Frame Rail Inner Reinforcement (Section)

Replacement

2
Prepare the surfaces (continued).

D
Clean the bond path areas and weld areas on the new section 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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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.

WARNING: Do not apply structural adhesive within 25 mm (1 in) of

the GMA weld locations. Applying structural adhesive within 25 mm
(1 in) of the GMA weld locations can cause weld failure.

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 Reinforcement (Section)

Replacement

3
Apply structural adhesive (continued).

A
Spread a thin coating of structural adhesive as a primer layer on the
bond paths on the vehicle and the new component (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 vehicle.

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 Front Frame Rail Inner Reinforcement (Section)

Replacement

4
Install the new component.

A
Put the new component into position and clamp it into place.

TIP: Make sure all 4 holes in the new Front Frame Rail Reinforcement
are aligned with the 4 holes in the existing Front Frame Rail Inner.

NOTE: Clamp any area that will not be attached with a fastener.

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B
Wipe off any excess adhesive.

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 Front Frame Rail Inner Reinforcement (Section)

Replacement

4
Install the new component (continued).

C
Perform resistance spot welding.
Installation Spot Weld (x12)

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 Reinforcement (Section)

Replacement

4
Install the new component (continued).

C
Perform resistance spot welding (continued).

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D
Remove any discoloration from the weld areas.

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 Front Frame Rail Inner Reinforcement (Section)

Replacement

4
Install the new component (continued).

E
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

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personnel and/or damage to the battery.

5
GMA weld the butt joint.

A
Identify the GMA weld location.

NOTE: Note that the GMA weld should not go from the top edge of
the panel to the bottom edge of the panel. Weld only the portion of
the Front Frame Rail Inner Reinforcement that does not contact the
Front Frame Rail Inner flanges to avoid transferring heat to the
Front Frame Rail Inner.

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 Front Frame Rail Inner Reinforcement (Section)

Replacement

5
GMA weld the butt joint (continued).

B
Perform GMA welding.

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.

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: Before GMA welding, a test weld using material of the same
gauge and type should be performed to make sure that the welding
equipment settings produce a satisfactory joint.

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 Front Frame Rail Inner Reinforcement (Section)

Replacement

6
Prime any bare metal with a suitable corrosion-resistant epoxy primer.

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7
Install the new Front Frame Rail Outer (Section).

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