Replace upper and lower ball joints on a 2024 Tesla Cybertruck Dual Motor. Due to the Cybertruck's heavy curb weight, exoskeleton design, and air suspension, ball joint service requires careful suspension support and air-suspension service mode handling.

Warnings

Tools required

Parts

• Upper ball joint (manufacturer-specified for Cybertruck front suspension) × 2 — OEM Tesla Cybertruck upper ball joint — refer to Service Manual
• Lower ball joint (manufacturer-specified for Cybertruck front suspension) × 2 — OEM Tesla Cybertruck lower ball joint — refer to Service Manual
• New cotter pins for ball joint castle nuts × 4 — OEM-spec cotter pin
• New steering knuckle pinch bolt × 2 — OEM single-use pinch bolt
• Replacement control arm bolts (if specified as single-use) × 4 — Refer to Tesla Service Manual — replace if marked TTY/single-use

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 / Jack Mode via the touchscreen to disable air suspension self-leveling before lifting.
4. Disconnect the 48V low-voltage battery per Tesla's documented Cybertruck procedure (location and connector differ from 12V Teslas — refer to Service Manual).
5. DO NOT touch, cut, or pierce ANY orange cable — these are 800V 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 front wheel lug nuts while vehicle is on the ground.
8. Raise vehicle on a lift rated for Cybertruck weight using Tesla-specified lift points; support with jack stands as a secondary safety.
9. Remove front wheels and set aside on the stainless body away from the vehicle (do not lean against exoskeleton).

Procedure

1. 1

   Inspect and document
   Photograph the front suspension assembly from multiple angles before disassembly. Note routing of any wheel speed sensor, brake hose, and air suspension lines so they can be returned to original positions. Inspect the strut, control arms, and tie rod ends for damage that may also need attention.
2. 2

   Disconnect sway bar end link from lower control arm
   Hold the end-link stud with an Allen key and remove the nut securing the sway bar link to the lower control arm. Swing the link out of the way. Replace the nut on reassembly if it is a self-locking type.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
3. 3

   Disconnect wheel speed sensor and brake hose bracket
   Unclip the front wheel speed sensor harness and any ABS/brake hose retainers from the knuckle and control arms so they will not be stressed when the knuckle is moved. Do not stretch or kink hoses.
4. 4

   Remove brake caliper and rotor
   Remove the caliper bracket bolts and suspend the caliper from the suspension with a hook or strap — do NOT let it hang by the brake hose. Slide off the rotor. Torque to OEM specification on reinstallation — refer to Tesla Service Manual.
   ⚠Never allow the caliper to hang from the flexible brake hose.
5. 5

   Remove steering knuckle pinch bolt (tie rod / steering link to knuckle)
   Remove the pinch bolt that secures the steering link/tie rod end to the knuckle. Discard the bolt — it is single-use. Carefully separate the joint without prying against any sensor or air-line bracket.
   ⚠️Steer-by-wire actuator: do not energize the vehicle with the steering link disconnected.
   Torque spec

   Pinch Bolt61 Nm (45 lb-ft)
6. 6

   Support knuckle and remove ball joint cotter pins and castle nuts
   Place a transmission/suspension jack under the lower control arm to support the knuckle and arm. Remove and discard the cotter pins on the upper and lower ball joint castle nuts, then loosen the castle nuts. Leave each nut threaded on a few turns initially to capture the joint when it pops free.
   Torque spec

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

   Separate ball joints from knuckle
   Use a press-style ball joint separator (preferred) to break each ball joint stud free from the knuckle. Avoid pickle-fork use if the boots will be reused, but as both joints are being replaced, either tool is acceptable. Remove the castle nuts fully once the tapers are loose.
   ⚠Do NOT strike the knuckle, control arm, or any stainless body panel with a steel hammer.
8. 8

   Remove knuckle from control arms (as required)
   With both upper and lower joints separated and the steering link disconnected, carefully maneuver the knuckle aside. Support it so it does not hang from any remaining harness. If the ball joints are integral to the control arms on this vehicle, leave the knuckle attached to the strut and proceed to control-arm-level service.
9. 9

   Remove old ball joints
   If the ball joints are pressed into the control arms, use a C-frame ball joint press with the manufacturer-specified adapters to drive each joint out. If the ball joints are integral to the arms, remove the upper and lower control arm bolts and replace the arms as assemblies. Inspect the control arm bores for damage, corrosion, and ovality. Refer to the Tesla Service Manual for whether the joints are serviceable separately on Cybertruck — if not, replace the complete control arm.
   ℹ️If unsure whether the joint is pressed-in or integral, stop and verify against the Tesla Service Manual before applying press force.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
10. 10

    Install new ball joints
    Press new ball joints squarely into the control arm bores using the correct adapters, ensuring they are fully seated against the shoulder. Install any retaining clip/snap ring if equipped. Verify the boot is undamaged and properly seated. If replacing complete control arms, install the new arms with new hardware where specified.
11. 11

    Reattach knuckle to ball joints
    Position the knuckle onto the upper and lower ball joint studs. Install the castle nuts and torque to specification, then advance the nut (do NOT back off) to align the next slot with the cotter pin hole. Install NEW cotter pins and bend the legs to retain.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
12. 12

    Reconnect steering link to knuckle
    Reseat the steering link into the knuckle and install a NEW pinch bolt. Torque to specification.
    Torque spec

    Pinch Bolt61 Nm (45 lb-ft)
13. 13

    Reinstall sway bar end link, brake components, and sensors
    Reattach the sway bar end link nut while holding the stud with an Allen key. Reinstall rotor and caliper, torquing caliper hardware to OEM specification. Re-clip the wheel speed sensor harness and brake hose into their original retainers.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
14. 14

    Reinstall wheels and lower vehicle
    Mount the wheels and snug the lug nuts. Lower the vehicle so suspension is at normal ride height with full vehicle weight on the wheels. Torque lug nuts in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
15. 15

    Final torque of control arm bolts at ride height
    With the vehicle's full weight on the wheels (suspension loaded at design ride height), final-torque the control arm pivot bolts. Torquing these at full droop will preload the bushings incorrectly and shorten their life.
    ⚠Control arm bolts MUST be torqued with weight on the wheels, not while suspension is hanging.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Verify all cotter pins are installed and bent correctly on both upper and lower ball joints.
2. Verify new pinch bolt and new sway bar link hardware (where applicable) are torqued to spec.
3. Reconnect the 48V low-voltage battery per Tesla procedure.
4. Exit Service/Jack Mode and allow the air suspension to self-level; confirm normal ride height front and rear.
5. Power on the vehicle and clear any chassis/steering DTCs. If the steering link was disturbed, perform steer-by-wire calibration via Tesla service software as required.
6. Perform a four-wheel alignment — mandatory after any ball joint or control arm service on Cybertruck.

Verification

• With wheels off the ground (in Jack Mode), grasp the tire at 12/6 and 9/3 positions and check for any play indicating loose ball joints — there should be none.
• Visually confirm both new cotter pins are installed, fully seated, and bent.
• Confirm no warning messages on the touchscreen related to steering, suspension, ABS, or air suspension after a road test.
• Drive at low speed in a safe area and listen for any clunks over bumps; perform a slow figure-8 to confirm steering response is smooth and centered.
• Confirm post-repair alignment specs are within Tesla Cybertruck factory tolerances.
• Reminder: while at the shop, check Tesla service interval items — brake fluid (every 2 years), cabin air filter (every 2 years), and front drive unit gear oil (Tesla now recommends periodic service, not 'lifetime').

More procedures for this vehicle