Control Arm Bushing - Front Upper

Replace the front upper control arm bushing on a 2024 Tesla Cybertruck Dual Motor. On this platform the front upper control arm is part of a multi-link air-suspension setup; in many cases Tesla supplies the upper arm as an assembly, so confirm bushing serviceability before ordering parts.

Warnings

Tools required

Parts

• Front upper control arm bushing (verify Tesla sells separately; otherwise full upper control arm assembly) × 1 — Manufacturer-specified Cybertruck front upper control arm bushing or assembly
• Ball joint cotter pin × 1 — OEM cotter pin matching ball joint stud
• Control arm pivot bolts (replace if single-use — verify in service manual) × 2 — Manufacturer-specified bolts

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. Disconnect the 48V low-voltage battery (Cybertruck uses 48V LV architecture, not 12V). Refer to the Tesla Service Manual for the LV battery location and disconnect sequence specific to Cybertruck.
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal on this 800V platform.
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 the air suspension self-leveling and vent reservoir pressure per on-screen prompts.
7. Loosen front wheel lug nuts while the truck is on the ground.
8. Lift the vehicle on a hoist or stands rated for Cybertruck weight; allow the front suspension to hang or support the lower control arm with a jack as required by the procedure.
9. Remove the front wheel on the affected side.

Procedure

1. 1

   Document and mark alignment references
   Before loosening anything, mark the position of any cam/eccentric bolts at the upper control arm pivots with a paint pen. Photograph the routing of any wiring harnesses or air suspension lines that pass near the upper arm. This shortens the post-repair alignment and prevents pinched lines.
2. 2

   Access the upper control arm
   Remove the front wheel well liner fasteners as needed for access to the upper arm and ball joint. Tuck or unclip any wheel-speed sensor harnesses, ride-height sensor links, or air lines that route along the upper arm. Do not stretch or kink air suspension lines.
   ⚠Air suspension lines are nylon/composite — a sharp kink can cause a slow leak that is difficult to diagnose later.
3. 3

   Support the knuckle / lower arm
   Place a jack with a wood block under the lower control arm or steering knuckle to support the corner. This relieves spring/strut load from the upper ball joint and prevents the knuckle from dropping when the upper joint is separated.
4. 4

   Disconnect the upper ball joint from the knuckle
   Remove and discard the cotter pin from the upper ball joint nut. Loosen and remove the ball joint nut. Separate the ball joint stud from the knuckle using a proper ball joint separator; avoid pickle-fork tools that can damage the boot if the joint is being reused.
   ⚠Do not strike the aluminum knuckle with a steel hammer to free the taper. Use a separator tool.
   Torque spec

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

   Remove the upper control arm pivot bolts
   Support the upper control arm. Remove the inboard pivot bolts/nuts securing the upper arm to the frame/subframe brackets. Note the orientation of any cam washers and the direction the bolts are installed (some chassis bolts must be driven in from a specific side for clearance).
   Torque spec

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

   Remove the upper control arm from the vehicle
   Maneuver the upper arm out of the chassis. Inspect the arm itself, the ball joint boot, and the mounting brackets for damage, cracks, or corrosion before proceeding.
   ℹ️If the bushing is not serviceable as a separate part on this Cybertruck arm, the entire upper control arm assembly must be replaced. Verify before pressing.
7. 7

   Press out the old bushing
   If the bushing is replaceable, secure the upper arm in a press with appropriate cradle/receiver adapters. Press the old bushing out in the manufacturer-specified direction. Do not heat the arm with an open flame — many modern Tesla suspension arms are forged or cast aluminum and will lose temper.
   ⚠Never apply press force directly on the control arm body — always through the bushing outer sleeve via a proper adapter.
8. 8

   Install the new bushing
   Lubricate the outer sleeve only with the lubricant specified by the bushing manufacturer (typically a soap-based assembly lube — never petroleum grease on rubber bushings). Press the new bushing in squarely until it is fully seated to the depth specified by the service manual. Confirm the bushing is not cocked.
9. 9

   Reinstall the upper control arm
   Position the arm in its brackets and insert the pivot bolts in the original orientation, including any cam washers aligned to your reference marks. Start nuts by hand; do NOT final-torque the pivot bolts yet — they must be torqued at ride height.
   ⚠Torquing rubber-bonded bushing pivots while the suspension hangs will preload the bushing and cause premature failure.
10. 10

    Reconnect the upper ball joint
    Seat the ball joint stud into the knuckle. Install the ball joint nut and torque to specification. Install a NEW cotter pin; if the slot does not align, tighten further (never loosen) until it does.
    Torque spec

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

    Reinstall harnesses, liner, and wheel
    Reroute any wheel-speed sensor harness, ride-height sensor link, and air lines exactly as photographed. Reinstall the wheel well liner. Mount the wheel and snug the lug nuts.
12. 12

    Lower vehicle and final-torque pivot bolts at ride height
    Lower the vehicle so full vehicle weight is on the wheels (or simulate ride height with the suspension loaded on a drive-on lift). With the suspension at normal ride height, torque the upper control arm pivot bolts to specification. Then final-torque the wheel lug nuts in a star pattern.
    ⚠Cybertruck air suspension may need to be exited from Jack Mode and allowed to relevel before bushings see true ride-height load.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reconnect the 48V low-voltage battery using Cybertruck-specific reconnect procedure.
2. Exit Jack/Service Mode on the touchscreen and allow the air suspension to fully relevel.
3. Cycle the suspension through ride-height settings (if user-selectable) to confirm the system pressurizes correctly with no leaks at moved/disturbed lines.
4. Inspect for any warning messages related to suspension, ride height, or steer-by-wire on the center display.

Verification

• Perform a four-wheel alignment on an alignment rack capable of supporting Cybertruck weight and reading its ride-height-dependent specs. This is mandatory after any upper control arm disturbance.
• Test drive at low speed first, listening for clunks from the upper arm area on bumps and during steering input — remember that on steer-by-wire there is no mechanical feedback, so audible/visual cues are your primary diagnostic.
• Recheck the area for air-line leaks — listen for hiss with the truck at full ride height, and verify no 'Air Suspension Fault' or 'Ride Height' warnings appear after a heat cycle.
• Re-torque wheel lug nuts after approximately 80–160 km (50–100 mi) of driving.
• Note: while doing front suspension work is a good time to inspect items that Tesla quietly recommends despite the 'no scheduled maintenance' marketing — including brake fluid (2-year service), cabin air filter (2-year service), and drive unit gear oil at the recommended Tesla intervals.

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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