my Tesla Model S Original (2012-2020) is showing signs of rust what should I do

Tesla Model S Plaid/Refresh (2021-present)

Error Codes

2-4 hours

Time

medium

Difficulty

medium

Severity

3 min read

552 words

Problem Statement

Learn how to diagnose and fix rust issues on your 2012-2020 Tesla Model S. Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Affected Component

Body/Interior

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Ensure proper ventilation when working with paint and solvents.
•Wear gloves and a dust mask when handling rust and chemicals.

Symptoms

•Visible rust spots on the body or undercarriage
•Paint bubbling or peeling in affected areas
•Corrosion around wheel wells or door edges
•Increased road noise or vibrations from rusted components
•Possible water leaks inside the vehicle due to compromised seals

Diagnostic Steps

1
Inspect the vehicle visually for rust in common areas such as wheel wells, undercarriage, and seams.
2
Check for bubbling paint or discoloration, which indicates rust formation beneath the surface.
3
Use a magnet to test for filler in suspected rust areas; if the magnet does not stick, it may indicate previous bodywork.
4
Inspect the drainage channels and seals for blockages or damage that could lead to moisture accumulation.
5
Assess the structural integrity by examining critical components like control arms, suspension parts, and subframes for signs of weakness or corrosion.

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•Wire brush
•Sandpaper
•Cleaning cloths
•Rust remover solution
•Paintbrush or spray can
•Rust-inhibiting primer
•Automotive paint
•Silicone sealant or automotive sealant

Parts Required

•Rust-inhibiting primer
•Clear coat paint

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Diagnostic Steps

1
Inspect the vehicle visually for rust in common areas such as wheel wells, undercarriage, and seams.
2
Check for bubbling paint or discoloration, which indicates rust formation beneath the surface.
3
Use a magnet to test for filler in suspected rust areas; if the magnet does not stick, it may indicate previous bodywork.
4
Inspect the drainage channels and seals for blockages or damage that could lead to moisture accumulation.
5
Assess the structural integrity by examining critical components like control arms, suspension parts, and subframes for signs of weakness or corrosion.

Solution

1. Preparation

Gather all necessary tools and materials.
Park the vehicle on a level surface and engage the parking brake.
Wear appropriate safety gear: gloves and a dust mask.

2. Clean Affected Areas

Tools Required: Wire brush, sandpaper, cleaning cloths, rust remover solution.
Use a wire brush to remove loose rust and debris from the affected areas.
Sand the area down to bare metal until smooth.
Clean the area with a rust remover solution and wipe it dry with a cloth.

3. Apply Rust Inhibitor

Tools Required: Paintbrush or spray can, rust-inhibiting primer.
Apply a coat of rust-inhibiting primer to the cleaned area, ensuring full coverage.
Allow the primer to dry according to manufacturer instructions (usually 1-2 hours).

4. Paint the Area

Tools Required: Automotive paint matching the vehicle color, clear coat.
Once the primer has dried, apply a matching automotive paint in thin layers for even coverage.
Allow the paint to dry completely, then apply a clear coat for additional protection.

5. Inspect and Seal

Tools Required: Silicone sealant or automotive sealant.
Inspect seams and joints around the repaired area.
Apply sealant where necessary to prevent moisture infiltration.