Replacement of an upper control arm on a 2024 Tesla Cybertruck Dual Motor AWD. The Cybertruck uses an air suspension system and a 48V low-voltage architecture, requiring specific precautions during suspension service.

Warnings

Tools required

Parts

• Upper control arm assembly (manufacturer-specified for Cybertruck Dual Motor) × 1 — Refer to Tesla EPC for correct front upper control arm — left/right specific
• New ball joint cotter pin × 1 — OEM-specification cotter pin
• Replacement control arm bolts (if specified as single-use by Tesla) × 2 — Refer to Tesla Service Manual — many Tesla suspension fasteners are torque-to-yield single-use

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Exit ALL doors with 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 (NOT a 12V system — confirm correct disconnect location and procedure in the service manual before proceeding).
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal (800V architecture on Cybertruck).
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 via touchscreen and activate Jack Mode / Transport Mode to disable air suspension self-leveling.
7. Loosen wheel lug nuts while vehicle is on the ground.
8. Chock the rear wheels.
9. Lift the front of the vehicle at the manufacturer-specified jack points and support on rated jack stands.
10. Remove the front wheel on the side being serviced.

Procedure

1. 1

   Support the lower control arm / knuckle
   Place a floor jack under the lower control arm (or knuckle) to support the suspension assembly. This prevents the knuckle from dropping and straining the brake hose, axle, and wiring once the upper arm is detached.
   ⚠Do not allow the knuckle to hang unsupported — this can damage the CV axle inner joint and the brake flex line.
2. 2

   Disconnect any wiring or sensor brackets attached to the upper control arm
   Inspect the upper arm for ride height sensor links, wiring clips, or brake line retainers. Carefully release them and set aside without straining the harnesses.
3. 3

   Remove the upper ball joint cotter pin and castellated nut
   Cut and discard the existing cotter pin. Loosen and remove the upper ball joint nut from the steering knuckle. Do not reuse the cotter pin.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
4. 4

   Separate the upper ball joint from the knuckle
   Use a press-style ball joint separator to break the taper. Avoid pickle-fork tools if the ball joint boot is being reused, as they will tear the boot. Once free, swing the knuckle outward carefully — remember the steering is steer-by-wire, and the knuckle is not constrained by a steering shaft.
   ⚠Steer-by-wire: the knuckle can rotate freely without resistance. Support it manually to avoid damaging the half-shaft or brake line.
5. 5

   Remove the upper control arm pivot bolts from the frame/subframe
   Support the arm by hand. Remove the inboard pivot bolts securing the upper control arm to the chassis bracket. Note bolt orientation and any alignment cams or shims for reinstallation.
   ℹ️If alignment cams or shims are present, mark their position before removal to preserve baseline alignment.
   Torque spec

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

   Remove the upper control arm from the vehicle
   Maneuver the arm out of the chassis bracket. Inspect the mounting points for corrosion, cracks, or distortion before installing the new arm.
7. 7

   Install the new upper control arm
   Position the new arm in the chassis bracket. Install the pivot bolts hand-tight only at this stage — final torque must be applied at ride height with the suspension loaded.
8. 8

   Reattach the ball joint to the knuckle
   Insert the ball joint stud into the steering knuckle. Install the castellated nut and torque to specification. Install a NEW cotter pin and bend the legs per service manual diagram. If the castellation does not align, tighten further (never loosen) until alignment is achieved.
   ⚠️Never back off the ball joint nut to align the cotter pin. Always tighten to the next slot.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
9. 9

   Reconnect wiring, sensors, and brackets
   Reattach any ride-height sensor link, wiring clips, and brake line retainers that were removed in Step 2. Verify the ride-height sensor link is undamaged — air suspension calibration depends on it.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

Reassembly

1. Reinstall the front wheel and hand-tighten the lug nuts.
2. Lower the vehicle until the tire is on the ground but the suspension is still partially supported (or fully on the ground for final torque).
3. With full vehicle weight on the wheels, torque the upper control arm pivot bolts to specification — this is critical for bushing life.
4. Torque wheel lug nuts to specification in a star pattern.
5. Exit Service Mode / Jack Mode via the touchscreen and allow the air suspension to self-level.
6. Reconnect the 48V low-voltage battery per the Tesla service procedure.
7. Power the vehicle on and allow it to complete its system self-checks.

Verification

• Confirm no fault messages on the touchscreen related to suspension, ride height, or steering (steer-by-wire system).
• With vehicle at normal ride height, visually verify the upper control arm is seated correctly and the ball joint cotter pin is properly installed and bent.
• Have a wheel alignment performed at a shop equipped to handle Cybertruck (heavy-duty alignment rack with appropriate weight rating). An alignment is mandatory after any control arm service.
• Test drive at low speed first, listening for clunks or unusual steering feel. With steer-by-wire, any unusual handling should be reported immediately and the vehicle re-inspected.
• Verify air suspension cycles correctly between ride height settings (Low / Standard / High) without faults.
• Note: while suspension service does not directly affect Tesla's published service intervals, this is a good time to inspect brake fluid (Tesla recommends replacement every 2 years) and tire wear (rotate every ~6,250 mi).

More procedures for this vehicle