Replacement of a front upper control arm on the 2024 Tesla Cybertruck Cyberbeast. The Cybertruck uses an air suspension system and a stainless exoskeleton — extra care is required to avoid scratching panels and to support the air strut correctly.

Warnings

Tools required

Parts

• Front Upper Control Arm Assembly (Cybertruck-specific) × 1 — Manufacturer-specified Cybertruck front upper control arm — refer to Tesla EPC
• Ball joint castle nut / prevailing-torque nut (single-use) × 1 — OEM replacement — single-use fastener if specified by Tesla
• Control arm pivot bolts (if specified single-use) × 2 — OEM replacement if marked single-use in service manual

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Exit ALL doors with 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. Disconnect the low-voltage battery. NOTE: Cybertruck uses a 48V low-voltage system (not 12V). Locate the LV battery per the Tesla Service Manual and disconnect using insulated tools.
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal.
5. 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.
6. Before lifting: enter Service Mode / Jack Mode on the touchscreen to disable air suspension self-leveling.
7. Chock the rear wheels.
8. Loosen the front wheel lug nuts while the wheel is still on the ground.
9. Raise the vehicle on a lift rated for Cybertruck weight, using the manufacturer-specified jacking pads/points only — the exoskeleton is not a load-bearing lift point.
10. Have replacement upper control arm and any single-use fasteners on hand before disassembly.

Procedure

1. 1

   Remove front wheel
   Fully remove the lug nuts and take the front wheel off the affected side. Set the wheel aside on its sidewall (do not lean against the exoskeleton).
2. 2

   Inspect for HV/LV routing
   Visually inspect the upper control arm area for any wiring harnesses, sensors, or cables routed along or near the arm. Cybertruck routes ride-height sensors and wheel speed sensor harnesses through this area. Confirm NO orange (HV) cabling is present in the work zone before proceeding.
   ⚠️If any orange cable is visible in the work area, STOP.
3. 3

   Support the lower control arm / knuckle
   Place a jack stand or transmission jack under the lower control arm to support the knuckle assembly once the upper ball joint is released. This prevents the knuckle from hanging on the brake hose, ride-height sensor link, or air spring.
   ⚠Do not allow the knuckle to drop — it can damage the air strut, brake line, or ride-height sensor linkage.
4. 4

   Disconnect ride-height sensor link (if attached to UCA)
   If the ride-height sensor link attaches to the upper control arm or its mounting area, carefully disconnect it. These sensors are fragile and required for air suspension operation.
   ⚠Damaged ride-height sensors will cause air suspension faults and require recalibration.
5. 5

   Disconnect sway bar end link (if it interferes)
   If the sway bar end link blocks UCA removal, separate it from the upper arm or knuckle. Hold the stud with an Allen key while loosening the nut to prevent the stud from spinning.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
6. 6

   Separate the upper ball joint from the knuckle
   Remove the cotter pin (if present) and loosen the upper ball joint nut. Back the nut off but leave it threaded on a few turns to protect the threads. Use a manufacturer-specified ball joint separator to break the taper. Avoid pickle forks if the boot is to be reused. Once free, fully remove the nut and lift the ball joint stud out of the knuckle.
   ⚠Do NOT strike the knuckle or control arm with a steel hammer. Use a dead-blow or the proper separator tool.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
7. 7

   Remove the upper control arm pivot bolts
   Locate the two inboard pivot bolts that secure the upper control arm to the chassis/frame. Note bolt orientation and any alignment cams or shims for reinstallation. Support the arm, then remove the bolts.
   ⚠If the bolts pass through alignment cams, mark cam position before removal to maintain a baseline alignment.
8. 8

   Remove the upper control arm
   Maneuver the upper control arm out of the chassis pocket and away from the knuckle. Compare the new arm side-by-side with the old one to confirm correct part, bushing orientation, and ball joint geometry.
9. 9

   Install the new upper control arm
   Position the new upper control arm into the chassis mounts. Hand-thread the pivot bolts (or new single-use bolts if specified). Do NOT final torque yet — bushings must be torqued at ride height.
10. 10

    Reattach upper ball joint to knuckle
    Raise the knuckle with the support jack to align the upper ball joint stud into the knuckle taper. Install a new ball joint nut and torque to specification. Install a new cotter pin if the design uses a castle nut.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
11. 11

    Reconnect sway bar link and ride-height sensor
    Reconnect the sway bar end link (hold the shaft with an Allen key while torquing) and reattach the ride-height sensor linkage. Confirm the sensor link is not bent or pre-loaded.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
12. 12

    Reinstall wheel and lower vehicle to load suspension
    Reinstall the front wheel and snug the lug nuts. Lower the vehicle so the full vehicle weight is on the wheels (or use drive-on alignment ramps / wheel cribs to simulate ride height while still allowing access to the pivot bolts).
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
13. 13

    Final-torque the upper control arm pivot bolts at ride height
    With suspension fully loaded at normal ride height, final-torque the upper control arm pivot bolts to specification. This prevents bushing pre-load.
    ⚠Torquing at full droop will twist the bushings and shorten arm life. Always torque under load.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
14. 14

    Final-torque wheel lug nuts
    Final-torque the lug nuts in a star pattern to specification.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Confirm all fasteners are torqued and no tools or rags are left in the wheel well.
2. Reconnect the 48V low-voltage battery using insulated tools.
3. Exit Service Mode / Jack Mode on the touchscreen and allow the air suspension to re-level.
4. Cycle the vehicle on and verify no suspension, ABS, ride-height, or steer-by-wire warnings appear on the dash.
5. Schedule a four-wheel alignment immediately — driving extended distances out of alignment will scrub the tires (Cybertruck tires are expensive and wear quickly under instant torque).

Verification

• Confirm no suspension, air-ride, or steering fault codes are active on the touchscreen.
• With vehicle on the ground, visually verify the upper control arm sits parallel to its mounting points and bushings are not visibly twisted.
• Bounce the front of the vehicle: it should settle smoothly with no clunks. Air suspension should re-level without faulting.
• Test drive at low speed in a safe area. Listen for clunks over bumps and verify steering feel is centered (steer-by-wire — yoke center is software-defined; significant offset suggests alignment is required).
• Perform a four-wheel alignment on a Tesla-capable rack. Confirm camber/caster are within Cybertruck spec.
• Reminder: while not part of this job, check Tesla's recommended service intervals — brake fluid every 2 years, cabin filter every 2 years, drive unit fluid initial 12,500 mi then 25,000–50,000 mi, and tire rotation every 6,250 mi (especially relevant after any alignment-affecting suspension work).

More procedures for this vehicle