Replacement of a rear upper control arm on a 2024 Tesla Cybertruck Dual Motor. The Cybertruck uses a multi-link rear suspension with air springs; this procedure addresses the upper arm only and requires final torque with the vehicle at ride height.

Warnings

Tools required

Parts

• Rear Upper Control Arm Assembly (manufacturer-specified for Cybertruck Dual Motor) × 1 — Tesla OEM rear upper control arm — refer to VIN-specific catalog
• New ball joint cotter pin × 1 — OEM-spec cotter pin matching ball joint stud
• New ball joint castle nut (if not reusable per OEM guidance) × 1 — OEM-spec

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 per Tesla service procedure (Cybertruck uses 48V architecture, not 12V — connector and location differ from legacy Teslas).
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal on the 800V system.
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. On the touchscreen, enable Jack Mode / Service Mode to disable air suspension self-leveling before lifting.
7. Loosen rear wheel lug nuts while the vehicle is on the ground.
8. Raise the vehicle on a lift rated for Cybertruck weight using manufacturer-specified lift points. Support with jack stands if using a floor jack.
9. Remove the rear wheel on the affected side.
10. Visually inspect the area for any orange HV cabling or HV components routed near the rear suspension before proceeding.

Procedure

1. 1

   Support the rear knuckle/upright
   Place a transmission jack or suspension support under the rear lower control arm / knuckle to support the assembly once the upper arm is disconnected. Do not let the half-shaft hang under its own weight.
2. 2

   Document arm orientation and any shims
   Photograph the upper control arm in place from multiple angles, noting any alignment cams, shims, or eccentric washers at the inboard mount. Mark eccentric positions with a paint pen so initial alignment can be approximated on reassembly.
   ℹ️A four-wheel alignment is required after this repair regardless of marking.
3. 3

   Disconnect any sensors or harnesses on the arm
   If a ride-height sensor link, ABS line clip, or wiring harness is routed along or attached to the upper control arm, carefully release it. Do not pull on connectors by the wires.
4. 4

   Remove the ball joint cotter pin and nut
   Straighten and remove the cotter pin from the upper ball joint stud. Loosen and remove the castle nut. Discard the cotter pin.
   Torque spec

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

   Separate the ball joint from the knuckle
   Use a proper ball joint separator tool to release the upper ball joint taper from the knuckle. Avoid hammering on the knuckle or the stainless body. If a pickle fork is used, be aware it can damage the boot — only acceptable if replacing the arm.
   ⚠Do not strike the stainless exoskeleton or any body panel.
6. 6

   Remove the inboard control arm bolts
   Support the arm and remove the inboard pivot bolt(s) securing the upper control arm to the subframe/cradle. Note bolt orientation for reinstallation.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
7. 7

   Remove the upper control arm
   Maneuver the arm out of the chassis. Inspect the mounting points, bushings on adjacent components, and ball joint seat on the knuckle for damage or contamination.
8. 8

   Compare old and new arms
   Lay the new arm next to the old one to confirm correct part: bushing orientation, ball joint angle, and any integrated brackets must match. Cybertruck rear upper arms may be side-specific.

Reassembly

1. Install the new upper control arm to the inboard chassis mount. Start the bolt(s) by hand to avoid cross-threading. Snug but do not final-torque yet.
2. Seat the ball joint stud into the knuckle. Install the castle nut and tighten to specification, then advance (never back off) to align the slot with the stud hole. Install a NEW cotter pin and bend per OEM practice. Torque ball joint nut — see Ball Joint Nut spec.
3. Reattach any harness clips, ABS line retainers, or ride-height sensor links removed earlier.
4. Reinstall the rear wheel. Snug lug nuts in a star pattern.
5. Lower the vehicle so the suspension is loaded at ride height (use drive-on ramps or lower fully to the ground). Air suspension should be allowed to settle to normal ride height after exiting Service/Jack Mode.
6. With the vehicle weight on the wheels, final-torque the inboard control arm bolt(s) — see Control Arm Bolts spec. This is critical to bushing life.
7. Torque the wheel lug nuts in a star pattern — see Wheel Lug Nuts spec.
8. Reconnect the 48V low-voltage battery.
9. Exit Service/Jack Mode on the touchscreen and allow air suspension to self-level.
10. Have a four-wheel alignment performed by a shop equipped for Cybertruck specs before returning the vehicle to normal use.

Verification

• Confirm no fault messages on the touchscreen related to suspension, ride height, ABS, or stability control.
• With the vehicle at normal ride height, verify even rear ride height side-to-side (Cybertruck displays/leverages air suspension height — compare to opposite corner).
• Inspect the new cotter pin is installed and bent correctly on the ball joint stud.
• Test drive at low speed first, listening for clunks over bumps which would indicate a loose pivot or improperly torqued arm.
• Verify alignment specs are within Tesla's published tolerance for Cybertruck Dual Motor — camber and toe at the rear are sensitive to upper arm replacement.
• Re-check inboard control arm bolt torque after the first 100–500 miles is good practice on bushing-pivot fasteners.
• Note: while performing rear suspension work, this is a good opportunity to confirm rear differential fluid service interval — Tesla now recommends drive unit gear oil service (initial ~12,500 mi, then every 25,000–50,000 mi); rear diff fluid spec is 75W-90 GL-5 if servicing separately.

More procedures for this vehicle