Replace the front upper control arm on a 2024 Model S Long Range AWD. The Model S uses a multi-link aluminum front suspension; the upper control arm bolts to the body and connects to the upper knuckle via a ball joint.

Warnings

Tools required

Parts

• Front upper control arm assembly (includes ball joint) × 1 — Manufacturer-specified Model S 2024 front upper control arm — verify by VIN
• Ball joint nut (single-use if specified by manufacturer) × 1 — OEM replacement fastener
• Upper control arm mounting bolts (if specified single-use) × 2 — OEM replacement fasteners

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 low-voltage battery, located in the front trunk under the nose cowl panel (some 2021+ Plaid use a 16V Li-ion under the rear seat — verify by VIN).
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. If equipped with air suspension, enter Service Mode and disable the suspension / set Jack Mode before lifting.
7. Loosen front wheel lug nuts while tires are on the ground.
8. Lift the vehicle using only Tesla-approved jack pad locations and support securely on jack stands rated for the vehicle's weight (Model S is ~4800 lb).

Procedure

1. 1

   Remove front wheel
   Remove the lug nuts and pull the front wheel off the side requiring service. Set aside on a soft surface to protect the finish.
2. 2

   Inspect and document
   Photograph the upper control arm orientation, fastener positions, and any alignment cam markings on the inboard mounting bolts before disassembly. Note bushing condition and any broken hardware.
3. 3

   Disconnect sway bar end link (if it interferes)
   If the sway bar end link blocks knuckle articulation needed to free the upper ball joint, separate the upper end-link nut. Hold the stud with an Allen key while loosening the nut. Reinstall later to spec.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
4. 4

   Support the knuckle / lower the assembly
   Place a jack stand or transmission jack lightly under the lower control arm to support the knuckle assembly. This prevents the knuckle from falling and stressing the CV axle, brake hose, and wheel speed sensor harness when the upper ball joint is released.
   ⚠Do not let the knuckle hang on the brake hose or ABS wiring — both can be damaged.
5. 5

   Separate upper ball joint from knuckle
   Remove the upper ball joint nut. Use a proper ball joint separator tool to press the ball joint stud out of the upper knuckle eye. Avoid pickle-fork tools that can tear the new boot if it is being reused, and avoid hammer blows directly on the aluminum knuckle.
   ⚠Aluminum knuckle — do not strike directly. Use a press-style separator.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
6. 6

   Remove inboard control arm mounting bolts
   Remove the two upper control arm mounting bolts where the arm attaches to the body/shock tower bracket. Mark the position of any alignment cams or eccentrics before removal so the new arm can be installed in approximately the same position.
   Torque spec

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

   Remove upper control arm
   Maneuver the upper control arm out of the chassis. Inspect the mating surfaces on the body bracket for corrosion, debris, or damage. Clean if needed.
8. 8

   Install new upper control arm — inboard side
   Position the new upper control arm into the body bracket. Install the mounting bolts hand-tight only at this stage. Final torque must be applied at ride height.
9. 9

   Reconnect ball joint to knuckle
   Insert the new ball joint stud through the upper knuckle eye. Install the ball joint nut and torque to specification. If the stud spins, apply gentle upward pressure on the joint while torquing.
   Torque spec

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

    Reconnect sway bar end link (if disconnected)
    Reinstall the sway bar end link nut, holding the shaft with an Allen key, and torque to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
11. 11

    Reinstall wheel
    Mount the wheel and install lug nuts hand-tight. Lower the vehicle so the full weight rests on the wheels before proceeding to final torquing.
12. 12

    Final-torque control arm bolts at ride height
    With the vehicle's full weight on the wheels (suspension at normal ride height), torque the upper control arm inboard mounting bolts to specification. This prevents bushing pre-load and premature failure.
    ⚠Skipping ride-height torquing is the single most common cause of suspension bushing failure on these cars.
    Torque spec

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

    Final-torque 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 all fasteners are torqued to specification.
2. Reconnect the 12V low-voltage battery in the frunk and reinstall the cowl panel.
3. If air suspension equipped, exit Service Mode / Jack Mode and allow the system to self-level.
4. Wake the vehicle and clear any chassis or suspension faults from the touchscreen alerts list.
5. Drive the vehicle to an alignment shop on a flatbed or short low-speed trip — do not drive at highway speed until aligned.

Verification

• Perform a 4-wheel alignment on a Tesla-capable rack — replacing an upper control arm changes camber and possibly caster.
• Test drive: confirm no clunking over bumps, no pulling, and no steering-wheel-off-center condition.
• Re-check ball joint nut and inboard control arm bolts after the first 100 miles for proper torque retention.
• Inspect the new ball joint boot for proper seating and no tears.
• Confirm no chassis, suspension, or stability-control alerts persist on the touchscreen after a short drive cycle.
• While the vehicle is up and apart, this is a good time to inspect the cabin air filter (replace every 2 years, or every 3 years on HEPA/Bioweapon Defense systems) and verify brake fluid service interval (every 2 years on Tesla's published schedule).

More procedures for this vehicle