Replacement of a front upper control arm on a 2024 Tesla Cybertruck Cyberbeast Tri Motor. The Cybertruck uses a heavy-duty multi-link front suspension with air springs; final fastener torquing must be done at ride height with vehicle weight on the wheels.

Warnings

Tools required

Parts

• Front Upper Control Arm Assembly (Cybertruck-specific, side-specific) × 1 — Tesla Cybertruck front upper control arm — refer to Tesla EPC for left/right designation
• Ball joint castle nut / prevailing-torque nut (single-use if specified by manufacturer) × 1 — OEM replacement fastener
• Control arm pivot bolts/nuts (replace if specified as single-use) × 1 — OEM replacement fasteners

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Exit ALL doors with the key fob away from the vehicle. Wait at least 2 minutes for HV systems to fully de-energize, even on this non-HV job.
3. Place the vehicle in Service Mode and Jack Mode via the touchscreen to disable air suspension self-leveling and lower the vehicle systems gracefully.
4. Disconnect the 48V low-voltage battery per Tesla's documented procedure for Cybertruck (location and connector differ from 12V Teslas — refer to the Tesla Service Manual for this vehicle).
5. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal.
6. If at any point you encounter an orange cable, an HV component, or are unsure if a system is de-energized: STOP and consult a Tesla-certified technician.
7. Loosen the front wheel lug nuts while the vehicle is still on the ground.
8. Raise the vehicle on a lift rated for Cybertruck weight, using only the manufacturer-specified lift points. Support with jack stands as a secondary safety measure.
9. Remove the front wheel on the affected side and set aside on a soft surface (the wheels are large/heavy).

Procedure

1. 1

   Inspect and document existing suspension state
   Before disassembly, photograph the upper control arm, ball joint, pivot bolts, and any alignment cam markings. Note any factory paint marks on bolts indicating final torque positions. Inspect the strut, lower control arm, and sway bar link for collateral damage that may have caused or resulted from upper arm failure.
2. 2

   Disconnect sway bar end link from upper control arm (if attached there)
   If the sway bar end link attaches to or near the upper control arm or knuckle path, separate the upper end of the link. Hold the ball stud with an Allen key inserted into the shaft hex while loosening the nut to prevent the stud from spinning.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
3. 3

   Support the knuckle / lower control arm
   Place a jack under the lower control arm or knuckle to support the suspension during ball joint separation. This prevents the knuckle from dropping and stressing the brake hose, ABS sensor harness, or any steer-by-wire actuator wiring.
   ⚠Do not let the knuckle hang freely — it can damage the brake line and wheel speed sensor harness.
4. 4

   Separate the upper ball joint from the steering knuckle
   Remove the cotter pin (if equipped) and loosen the upper ball joint nut. Back the nut off but leave it threaded a few turns to catch the joint. Use a press-style ball joint separator (preferred) to release the taper. Avoid pickle-fork separators if the ball joint boot will be reused. Once released, fully remove the nut and lift the ball stud out of the knuckle.
   ⚠Do not strike the knuckle or surrounding aluminum/cast components with a steel hammer — use a dead-blow or controlled press to avoid cracking castings.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
5. 5

   Mark and remove inboard pivot bolts
   Mark the position of any alignment cam bolts/washers relative to the frame bracket so the new arm can be installed at approximately the same caster/camber setting (a full alignment is still required afterward). Remove the inboard pivot bolt(s)/nut(s) securing the upper control arm to the chassis bracket.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove the upper control arm
   Maneuver the upper control arm out of the chassis bracket and out of the wheel well. Be mindful of routing for any wiring or air suspension lines passing nearby — do not pull on harnesses.
7. 7

   Compare old and new arm
   Place the old and new control arms side by side. Verify length, ball joint orientation, bushing style, and any sensor mounting tabs match. Confirm left/right designation. Cybertruck front suspension components are model-specific — do not substitute parts from Model S/X.
8. 8

   Install the new upper control arm — inboard pivot
   Position the new arm into the chassis bracket. Install the pivot bolt(s) and nut(s) hand-tight only at this stage. If alignment cams are present, set them to the marks made during removal as a starting point. Final torque will be applied later with the vehicle at ride height.
   ⚠Do NOT final-torque pivot bolts yet — bushings must be loaded at ride height.
9. 9

   Reconnect the upper ball joint to the knuckle
   Insert the ball joint stud through the knuckle. Install the manufacturer-specified nut (use a new nut if the OEM specifies single-use). Torque to specification. Install a new cotter pin if applicable.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
10. 10

    Reconnect sway bar end link
    Reattach the sway bar end link, holding the ball stud shaft with an Allen key while torquing the nut to spec.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
11. 11

    Reinstall wheel and lower vehicle
    Reinstall the front wheel and snug the lug nuts. Lower the vehicle until the full weight of the Cybertruck rests on the tires (ride height). The air suspension may need to remain in Jack Mode until the 48V battery is reconnected and the system is reactivated — alternatively, lower onto drive-on ramps or a flat-deck lift to load the suspension before final torque.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
12. 12

    Final-torque inboard control arm pivot bolts at ride height
    With the full vehicle weight on the wheels and suspension at normal ride height, torque the upper control arm inboard pivot bolt(s) to specification. This is critical — torquing at full droop will pre-stress the bushing and shorten its life dramatically.
    ⚠️CRITICAL torque step. Under-torqued pivot bolts can loosen and cause loss of vehicle control. Verify with a calibrated torque wrench.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
13. 13

    Final lug nut torque
    With the wheel loaded, perform final torque on the lug nuts in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Confirm all fasteners are torqued and any cotter pins / retainers are installed.
2. Reconnect the 48V low-voltage battery per Tesla procedure for Cybertruck.
3. Exit Jack Mode and Service Mode via the touchscreen and allow the air suspension to recalibrate to normal ride height.
4. Cycle the vehicle on, observe for any suspension, ABS, steer-by-wire, or air suspension fault messages on the dash/center display.
5. Clear any DTCs that resulted from the disconnect, if applicable, using the Tesla service interface.

Verification

• Visually inspect the new control arm seated correctly with no interference at full steering lock and full air suspension travel (raise/lower via touchscreen modes).
• Confirm no warning messages on the center display related to suspension, steering, or stability control.
• Test drive at low speed first, listening for clunks, binding, or pull. Steer-by-wire steering effort should feel symmetric left/right.
• Perform a full four-wheel alignment — mandatory after any control arm replacement on the Cybertruck. The vehicle's rear-steer system may also require alignment-related calibration.
• If the vehicle exhibits any steering centering offset or driver-assist warnings post-repair, a steer-by-wire / ADAS calibration through Tesla's service software may be required.
• Re-check pivot bolt torque after the first 100–200 miles as good practice on safety-critical suspension fasteners.
• Note: while this job does not involve fluids, this is a good opportunity to confirm Tesla's other interval items are current — brake fluid (every 2 years), cabin air filter (every 2 years), and drive unit gear oil (Tesla now recommends periodic service rather than 'lifetime').

More procedures for this vehicle