Replace the front upper control arm bushing on a 2024 Tesla Model 3 Performance. Note: on most Model 3 platforms the front upper control arm is supplied as an assembly with integrated bushings — individual bushing replacement is typically not serviced separately, and the entire upper control arm is replaced.

Warnings

Tools required

Parts

• Front Upper Control Arm Assembly (with integrated bushing) — manufacturer-specified for 2024 Model 3 Performance × 1 — Refer to Tesla parts catalog for 2024 Model 3 Performance front upper control arm
• New cotter pin for ball joint nut × 1 — OEM-spec cotter pin
• Ball joint castle nut (replacement recommended) × 1 — OEM-spec

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 12V (or Li-ion low-voltage) battery. On 2024 Model 3, the low-voltage battery is located behind the right rear seat back panel on most builds; some 2024+ units use a lithium 12V/16V unit under the floor — confirm before disconnecting.
4. DO NOT touch, cut, or pierce ANY orange cable — these are 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. Chock the rear wheels.
7. Loosen the front wheel lug nuts while the vehicle is on the ground.
8. Raise the front of the vehicle using Tesla-specified front jack points and pucks; support securely on jack stands.
9. Remove the front wheel on the affected side.
10. Inspect the upper control arm and surrounding components — confirm the bushing is the failure point and that a replacement assembly is available.

Procedure

1. 1

   Document and photograph baseline
   Take reference photos of the upper control arm orientation, ball joint position, and any alignment marks. This Tesla uses pressed/molded suspension components and orientation matters for reassembly.
2. 2

   Disconnect sway bar end link (if required for access)
   If access to the upper control arm is obstructed, disconnect the front sway bar end link at the strut/control arm. Hold the stud with an Allen key while loosening the nut to prevent stud spin.
   Torque spec

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

   Remove cotter pin and loosen upper ball joint nut
   Straighten and remove the cotter pin from the upper ball joint castle nut. Loosen the ball joint nut but leave it threaded on by a few turns to retain the knuckle while breaking the taper.
   ⚠Discard the cotter pin — never reuse.
4. 4

   Separate upper ball joint from steering knuckle
   Use a proper ball joint separator tool to break the taper between the upper ball joint stud and the steering knuckle. Do NOT strike the aluminum knuckle with a hammer. Once separated, fully remove the castle nut and lift the knuckle clear of the upper ball joint stud. Support the knuckle so it does not hang on the brake hose, ABS sensor wiring, or CV axle.
   ⚠️Do not let the steering knuckle drop — it will damage the brake line and ABS wiring.
   Torque spec

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

   Mark and remove upper control arm chassis bolts
   Mark the position of any cam/eccentric washers if present on the inboard mounting bolts so alignment is approximately preserved. Support the control arm and remove the inboard mounting bolt(s) securing the upper control arm to the chassis. Remove the upper control arm assembly from the vehicle.
   Torque spec

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

   Install replacement upper control arm assembly
   Position the new manufacturer-specified upper control arm into the chassis mount. Install the inboard bolt(s) and any eccentric washers in their marked orientation. Hand-tighten only at this stage — final torque is applied with the vehicle at ride height.
   ℹ️Do not fully torque the control arm bolts yet — bushings must be clamped at ride height to avoid preload that will tear the rubber.
7. 7

   Reconnect upper ball joint to steering knuckle
   Lift the steering knuckle onto the new upper control arm ball joint stud. Install a new castle nut and torque to specification. Continue tightening (do NOT back off) only as far as necessary to align the slot with the cotter pin hole. Install a NEW cotter pin and bend the legs per standard practice.
   ⚠Always advance the nut to align the cotter pin hole — never loosen.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
8. 8

   Reconnect sway bar end link (if disconnected)
   Reattach the sway bar end link, holding the stud with an Allen key while torquing the nut.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
9. 9

   Reinstall wheel and lower vehicle
   Reinstall the front wheel. Snug the lug nuts, then lower the vehicle until the suspension is loaded at normal ride height (tire on ground, vehicle weight on wheels).
   Torque spec

   Wheel Lug Nuts136 Nm (100 lb-ft)
10. 10

    Final torque of control arm chassis bolts at ride height
    With the vehicle's full weight on the wheels and suspension at ride height, final-torque the upper control arm inboard mounting bolt(s) to specification. This is critical — torquing while suspension is drooping will preload the bushing and cause early failure.
    ⚠️Skipping the at-ride-height torque step will destroy the new bushing within months.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
11. 11

    Final torque of wheel lug nuts
    Torque the wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Verify cotter pin is installed and bent on the upper ball joint nut.
2. Verify all removed fasteners are reinstalled and torqued.
3. Reconnect the 12V (or LV) battery.
4. Close the right rear seat back panel (or under-floor LV access cover) and restore interior trim.
5. Wake the vehicle and allow systems to re-initialize. Check for any chassis or stability-control warnings on the touchscreen.
6. Take the vehicle to an alignment rack — front camber/caster will be affected by upper control arm replacement and MUST be set to spec.

Verification

• Confirm no warning messages on the center display related to stability control, ABS, or steering.
• With vehicle on the ground, perform a visual inspection: bushing seated, no contact between control arm and chassis at full droop or compression.
• Bounce-test the front of the vehicle — listen for clunks, knocks, or squeaks from the upper arm area.
• Test drive at low speed over bumps and through turns; listen for ball joint or bushing noise.
• Verify steering returns to center properly and the vehicle tracks straight.
• Perform (or have performed) a 4-wheel alignment — required after any control arm service on Model 3.
• Re-inspect the upper ball joint cotter pin and torque marks after the first 100 miles.
• Note: while the vehicle is up, consider Tesla's actual service intervals — brake fluid every 2 years, cabin air filter every 2 years, and tire rotation every 6,250 mi. None are required for this job but are commonly overdue on 2024 vehicles approaching 1-year service.

More procedures for this vehicle