Replacement of the front upper control arm on a 2024 Tesla Cybertruck Dual Motor AWD. The Cybertruck uses an aluminum-intensive front suspension with standard air suspension, and final torque on control arm fasteners must be done at ride height with the vehicle's weight on the wheels.

Warnings

Tools required

Parts

• Front upper control arm assembly (Cybertruck-specific) × 1 — OEM Tesla Cybertruck front upper control arm — verify by VIN
• Ball joint cotter pin × 1 — New cotter pin — never reuse
• Control arm pivot bolts/hardware (if specified as single-use) × 1 — Refer to Tesla Service Manual — replace if listed as TTY/single-use

Preparation

1. Park on level ground, place in P, and engage the 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 per Tesla Cybertruck service procedure (note: this is 48V, not 12V — connectors and disconnect sequence differ from other Teslas).
4. DO NOT touch, cut, or pierce ANY orange cable — these are 800V 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 the touchscreen Service / Jack Mode to disable air suspension self-leveling and lock the vehicle at the desired ride height.
7. Loosen the front wheel lug nuts while the vehicle is still on the ground.
8. Lift the vehicle using Tesla-approved lift points and Cybertruck-specific pad adapters. Support with rated jack stands if not on a lift.
9. Remove the front wheel on the side being serviced.
10. Inspect the work area for any orange HV cabling or sensor harnesses that may be near the upper control arm; reroute or protect as needed.

Procedure

1. 1

   Document alignment and suspension reference points
   Before disassembly, note camber bolt orientation (if equipped) and any factory paint marks on the upper control arm mounting hardware. Photograph the assembly. This helps return the vehicle close to spec before the mandatory alignment.
2. 2

   Support the lower control arm / knuckle
   Place a transmission jack or floor jack with a soft pad under the lower control arm to support the knuckle assembly. This prevents the knuckle from dropping and damaging the CV axle, brake hose, or wheel speed sensor harness when the upper ball joint is released.
   ⚠Do NOT let the knuckle hang by the brake hose or ABS sensor wire.
3. 3

   Disconnect any wiring or sensors routed along the upper control arm
   Carefully release any harness clips, ride-height sensor links, or air line retainers attached to the upper control arm. Cybertruck routes ride-height and air suspension lines near the front suspension — handle gently and do not stretch.
   ⚠Air suspension lines are pressurized when the system is active. Confirm Service/Jack Mode has bled or isolated the system before disturbing lines.
4. 4

   Remove the upper ball joint cotter pin and castle nut
   Straighten and remove the cotter pin from the upper ball joint stud. Loosen and remove the ball joint castle nut. Discard the cotter pin — a new one is mandatory on reassembly.
5. 5

   Separate the upper ball joint from the steering knuckle
   Use a press-style ball joint separator to break the taper between the upper ball joint stud and the knuckle. Avoid pickle-fork tools if possible, as they can damage the ball joint boot if the joint will be reused, and can mar aluminum knuckles.
   ⚠Do not strike the aluminum knuckle with a hammer to free the taper — use a controlled press separator.
6. 6

   Remove the upper control arm pivot bolts
   Support the control arm. Remove the inboard pivot bolts/nuts securing the upper control arm to the frame/subframe mounting points. Note bolt orientation and any alignment cams. Remove the control arm from the vehicle.
7. 7

   Inspect mounting points and related components
   Inspect the frame/subframe mounting bores for cracks, corrosion, or elongation. Inspect the upper ball joint taper bore in the knuckle for damage. Inspect the strut, sway bar end link, and lower ball joint boots while access is open.
8. 8

   Install the new upper control arm — pivot bolts hand-tight
   Position the new upper control arm at the frame mounts. Install the pivot bolts in the original orientation. Snug them, but DO NOT final-torque yet — final torque must occur with the suspension loaded at ride height.
   ⚠Torquing pivot bolts now will pre-load the bushings in the drooped position and cause premature failure.
9. 9

   Reconnect the upper ball joint to the knuckle
   Raise the knuckle with the support jack and seat the ball joint stud into the knuckle taper. Install the castle nut and torque to specification. Continue tightening (do not back off) only as needed to align the slot with the stud's cotter pin hole, then install a NEW cotter pin and bend the legs per OEM pattern.
   ⚠️Never loosen the castle nut to align the cotter pin — only tighten further within spec range. A loose ball joint can cause loss of control.
   Torque spec

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

    Reattach wiring, sensor links, and air lines
    Re-secure any harness clips, ride-height sensor link, and air suspension line retainers to the new control arm. Confirm no chafing points and full suspension travel clearance.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
11. 11

    Reinstall wheel and lower vehicle
    Mount the front wheel and snug the lug nuts. Lower the vehicle so the full weight of the truck is on the wheels (suspension at normal ride height). If on a lift, use a drive-on alignment platform or lower fully to the ground.
    Torque spec

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

    Final-torque control arm pivot bolts at ride height
    With the vehicle's full weight on the wheels and the suspension at normal ride height, final-torque the upper control arm pivot bolts to specification. This is a critical step — pivot bushings must be clocked at static ride height.
    ⚠️Skipping ride-height torquing will destroy the new bushings within a few thousand miles.
    Torque spec

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

    Final-torque wheel lug nuts in star pattern
    Torque the lug nuts in a star (cross) pattern to the verified specification. Re-check after a short test drive.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reconnect the 48V low-voltage battery following Cybertruck-specific procedure.
2. Exit Service/Jack Mode and allow the air suspension to re-pressurize and self-level. Verify normal ride height front-to-rear and side-to-side.
3. Cycle the steering yoke lock-to-lock with the vehicle stationary and verify steer-by-wire reports no faults on the touchscreen.
4. Clear any chassis or suspension fault codes that may have been logged during the repair (via Tesla service interface — do not attempt without proper access).
5. Schedule and perform a four-wheel alignment. The vehicle should not be returned to road use without alignment after upper control arm replacement.

Verification

• Confirm no suspension, ABS, ride-height, or steer-by-wire warnings on the touchscreen after a key-on cycle.
• With the vehicle on the ground, visually verify the upper control arm sits parallel to its mounting plane and the ball joint boot is intact and seated.
• Confirm the new cotter pin is installed and properly bent on the upper ball joint castle nut.
• Test drive at low speed first, listening for clunks, binding, or steer-by-wire anomalies. Then road test at highway speed and verify straight tracking and no vibration.
• Recheck wheel lug torque after approximately 80–160 km (50–100 mi) of driving.
• Note: while performing front suspension service, this is a good time to inspect brake fluid age (Tesla recommends replacement every 2 years) and front drive unit gear oil interval (initial service ~12,500 mi, then every 25,000–50,000 mi).

More procedures for this vehicle