Replacement of a front lower control arm on a 2024 Tesla Cybertruck Dual Motor. The Cybertruck uses air suspension and a heavy-duty multi-link front suspension; final fastener torque must be done at ride height with vehicle weight on the wheels.

Warnings

Tools required

Parts

• Front lower control arm assembly (manufacturer-specified for Cybertruck Dual Motor) × 1 — Refer to Tesla EPC for VIN-specific part
• New ball joint cotter pin × 1 — OEM specification
• Control arm pivot bolts (replace if single-use / TTY — verify with Tesla Service Manual) × 2 — Refer to Tesla Service Manual

Preparation

1. Park on level ground, place in P, engage parking brake, and chock the rear wheels.
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 air suspension into Jack Mode via the touchscreen (Controls → Service → Jack Mode) before lifting, then disable the vehicle.
4. Disconnect the 48V low-voltage battery per Tesla Service Manual procedure (Cybertruck uses 48V LV — NOT 12V). Insulate the disconnected terminal.
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 front of the vehicle at the manufacturer-specified lift points and support on rated jack stands. Confirm stability before going underneath.
9. Remove the front wheel on the affected side.
10. Inspect the surrounding area for routing of brake hose, wheel speed sensor harness, ride height sensor link, and any air suspension lines so they can be supported and protected during the job.

Procedure

1. 1

   Support the lower suspension
   Place a jack under the steering knuckle / lower spring perch area to support the suspension and prevent it from dropping when fasteners are released. Do not lift the vehicle off the stands — only support the knuckle.
   ⚠An unsupported knuckle can fall under its own weight and damage the strut, CV joint boot, ride height sensor link, or brake hose.
2. 2

   Disconnect the sway bar end link from the lower arm (if attached there)
   If the sway bar end link attaches to the lower control arm on this configuration, hold the link's internal hex with an Allen key and remove the nut. Swing the link out of the way. If the link instead attaches to the strut on this vehicle, leave it and skip this step.
   Torque spec

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

   Release the lower ball joint
   Remove and discard the cotter pin from the lower ball joint castle nut. Loosen the ball joint nut several turns but do not remove it yet — leave it threaded on to catch the knuckle as it releases. Use a press-style ball joint separator to break the taper. Avoid pickle forks if the ball joint boot is being reused.
   ⚠Do not strike the knuckle or control arm with a hammer to free the taper — risk of damage to the steer-by-wire-controlled knuckle and surrounding sensors.
4. 4

   Separate the ball joint and support the knuckle
   Once the taper releases, fully remove the ball joint nut and lift the knuckle off the lower ball joint stud. Support the knuckle with a strap or by resting it on the jack so that no load hangs on the brake hose, wheel speed sensor harness, or ride height sensor link.
5. 5

   Disconnect ride height sensor link if mounted to the arm
   If the air suspension ride height sensor link attaches to the lower control arm, carefully detach it. Handle the sensor and its link gently — replacement requires recalibration.
   ⚠Damaging the ride height sensor will trigger air suspension faults and require replacement plus calibration.
6. 6

   Mark and remove the inboard control arm pivot bolts
   Mark the position of any cam/eccentric washers if equipped, to aid initial alignment setup. Remove the inboard pivot bolts that secure the lower control arm to the subframe/cradle. Support the arm as the last bolt comes free.
   ℹ️Some Tesla suspension pivot bolts are single-use. Verify reuse policy in the Tesla Service Manual before reinstallation.
7. 7

   Remove the lower control arm
   Maneuver the control arm down and out of the subframe. Inspect the bushing pockets and ball joint mating surface on the knuckle for damage, corrosion, or debris. Compare the new arm to the old arm to confirm correct part.
8. 8

   Install the new lower control arm — inboard side
   Position the new control arm into the subframe pockets. Install the inboard pivot bolts hand-tight only. Do NOT final-torque yet — the bushings must be clamped at ride height to avoid premature bushing failure.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
9. 9

   Reattach the ball joint to the knuckle
   Lower the knuckle onto the ball joint stud. Install a new castle nut (or reuse per OEM) and torque to specification. Continue tightening only as needed to align the next castellation with the cotter pin hole — never back off to align. Install a NEW cotter pin and bend the legs per OEM practice.
   Torque spec

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

    Reconnect sway bar end link and ride height sensor link
    Reinstall the sway bar end link nut while holding the link shaft with an Allen key. Reconnect the ride height sensor link to the control arm if it was removed.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
11. 11

    Reinstall the wheel
    Mount the front wheel and install the lug nuts. Snug them in a star pattern. Final torque will be performed with the wheel on the ground.
    Torque spec

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

    Lower vehicle to ride height and final-torque control arm bolts
    Lower the truck so the suspension is loaded at normal ride height (drive-on ramps or an alignment-rated drive-on lift is ideal). With full vehicle weight on the wheels, final-torque the inboard control arm pivot bolts to specification. This prevents preloading the bushings.
    Torque spec

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

    Final-torque wheel lug nuts
    With the vehicle on the ground, 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 accounted for; verify the new cotter pin is installed at the ball joint.
2. Reconnect the 48V low-voltage battery per Tesla Service Manual procedure.
3. Exit Jack Mode via the touchscreen and allow the air suspension to self-level. Confirm no air suspension or chassis fault messages appear.
4. Cycle the steering lock-to-lock with the vehicle stationary on a smooth surface to allow the steer-by-wire system to recalibrate end stops as needed; verify no steering fault warnings.
5. Perform a four-wheel alignment — required after any control arm replacement on this chassis.
6. Reset/relearn ride height calibration if Tesla service procedure calls for it after suspension component replacement.

Verification

• No suspension, steering, or air suspension warnings on the touchscreen after a key cycle and short test drive.
• Vehicle sits at correct ride height on both sides; compare fender-to-ground measurements left vs right.
• Test drive on smooth and rough pavement: no clunks from the front end, steering tracks straight at constant throttle, no pull.
• Re-check ball joint cotter pin and control arm bolt witness marks after the first 100–200 km / 60–120 mi for any movement.
• Confirm alignment printout shows all front specs in green within Tesla's published tolerances.
• Note: Cybertruck has no scheduled maintenance for suspension, but Tesla recommends brake fluid service every 2 years and tire rotation every ~6,250 mi — a good time to check both since the wheel is already off.

More procedures for this vehicle