CT Bed Divider - Anatomy of Breaking the Latch

[Bobo_LaDouche]

The bed divider does not always fit in the bed correctly due to fit tolerance errors, and numerous comments on these threads discuss this problem. Not only did mine not fit, but I broke the latch mechanism on my first trial install. Tesla was very good to replace this, but I replaced this through the dealer because Tesla Online disappeared and could not be contacted once delivery occurred. Since the broken divider was going to be junked, Tesla allowed me to keep it. So I took it apart to find out what happened.

The gear teeth bent, and that was the cause of the failure. The photo shows this. The teeth are non-magnetic, so probably aluminum.

I fixed the mechanism by installing an extension spring on the left side, at the location shown in the second photo. This pushes the latch outward, allowing it to catch. The right side mechanism has been restored to normal and thus closes with an extension fit as designed. The first photo is the symptom - latch does not close; the gears can not be accessed without removing two rivets.

When your latch breaks, grind off the teeth, but keep the two lower teeth on the left side. This keeps the angle correct, and keeps the mechanism from "jack-knifing" by falling down. Otherwise, a spacer will be needed. Two rivets must be removed, and replaced (1"); nuts and bolts will not fit. Anyways, I have a new bed divider and a fixed one. I think the fixed one is better since it does not have the crazy-chain linkage and aluminum tooth gears.

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[Gigahorse]

I wonder if the 3rd party manufactures have figured this out and improved on it?
Looks like the rivets could be replaced by small bolts?
Thanks for documenting this for the rest of us.

 

[Bobo_LaDouche]

A photo of the finished product, before re-assembly, and a short movie of the operation with the spring while assembled.

Note the screw that I tapped into the body, this is necessary to keep the mechanism geometry in-line, and the screw acts like a spacer.

In hindsight, this probably could be fixed by removing only one rivet (3rd from left), and then grinding the gears from only the left side. This could be replaced by a nut/bolt and not a rivet, since it is shorter. Gear teeth on the right side probably do not matter.

Note that the assembly can only be removed from the body in one of two ways when damaged: either remove the rivet while un-assembled (hand drill), or use a hammer to lay the mechanism to original flat, thus really stretching the gear teeth. I used the hammer with the square handle removed.

It is also a matter to make the entire device fit into the truck bed, and shaving in every location has been proposed, including setting the truck bed flat, straightening the rails, cutting the feet of the Divider, etc. The easiest solution is to grind a little (15%) from the top of each of the 4 metal dowels on the ends of the CT Divider.

 

[PungoteagueDave]

Thanks. Mine is also broken like this, good to see the internals. I’m past the return window a couple weeks, not sure what to do. Will try a service request.

 

[OldDirtyRobot]

I wonder if the 3rd party manufactures have figured this out and improved on it?
Looks like the rivets could be replaced by small bolts?
Thanks for documenting this for the rest of us.

3rd parties are manufacturing the Tesla one.

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