Replace the upper ball joint on a 2024 Tesla Model S Plaid. On Plaid trim with air suspension and forged aluminum upper control arms, the ball joint is typically integrated into the upper control arm assembly — verify availability of a standalone ball joint before starting, as full UCA replacement may be required.

Warnings

Tools required

Parts

• Upper ball joint assembly (or complete upper control arm if integrated) × 1 — Manufacturer-specified upper ball joint / UCA for 2024 Model S Plaid
• Cotter pin (castle nut) × 1 — OEM-spec cotter pin matching ball joint stud
• Pinch bolt (if disturbed) × 1 — OEM single-use pinch bolt

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 12V (or 16V lithium under rear seat on 2021+ Plaid) low-voltage battery. Verify by VIN which system this vehicle uses.
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. Before disconnecting 12V/16V: use the touchscreen to enable Jack Mode (Controls > Service > Jack Mode) to disable air suspension self-leveling and depressurize the system.
7. Loosen wheel lug nuts while the vehicle is still on the ground.
8. Identify which side (LH/RH) is being serviced and confirm replacement part on hand matches Tesla's current part configuration for this VIN.
9. Inspect the upper control arm — if the ball joint is integrated (non-serviceable), source a complete UCA assembly before proceeding.

Procedure

1. 1

   Lift vehicle and remove wheel
   With Jack Mode active and 12V disconnected, lift at the Tesla-approved jack point on the rocker using a rubber pad. Support the vehicle on rated jack stands. Remove the wheel lug nuts and set the wheel aside. Never work under a vehicle supported only by a jack.
   ⚠️Jacking outside the approved pad locations can puncture the HV battery enclosure on the floor pan.
2. 2

   Inspect and document
   Photograph the upper ball joint, control arm orientation, and any alignment shim/cam markings. Note the position of any eccentric bolts on the upper control arm — these affect camber and must be returned to the same index.
3. 3

   Support the knuckle / lower control arm
   Place a secondary jack under the lower control arm or knuckle to support its weight and prevent the strut/CV joint from drooping when the upper joint is released. Apply light upward pressure only — do not preload the suspension.
4. 4

   Disconnect ABS / brake / wear-sensor wiring as needed
   If routing of the ABS sensor harness or brake wear sensor harness interferes with ball joint access, unclip from the knuckle bracket. Do not stretch or pull on the wiring. Front Plaid motor harnesses may share routing — leave any orange cabling untouched.
   ⚠️Stop immediately if you encounter any orange high-voltage cabling.
5. 5

   Remove cotter pin and ball joint nut
   Straighten and remove the cotter pin from the ball joint castle nut. Hold the ball joint stud from rotating (internal hex if equipped) and loosen the castle nut. Back the nut off but leave it threaded a few turns on the stud to catch the knuckle when the joint releases.
6. 6

   Separate ball joint from knuckle
   Use a proper ball joint separator tool to release the taper. Do NOT use a pickle fork on the boot if the joint is being reused, and do NOT hammer the aluminum knuckle. Once released, fully remove the castle nut and lift the upper arm clear of the knuckle.
   ⚠Aluminum knuckle — impact damage is not repairable. Use press-style separator only.
7. 7

   Remove ball joint or upper control arm
   If the ball joint is a serviceable bolt-in unit, remove its retaining hardware from the upper control arm. If it is integrated into the UCA (most likely on this vehicle), remove the inner UCA bolts at the frame/subframe — note eccentric/cam alignment first — and remove the entire upper control arm assembly.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
8. 8

   Install new ball joint / upper control arm
   Install the new ball joint or UCA in the same orientation as removed. Hand-thread inner control arm bolts (if removed) to the original cam alignment marks. Do not fully torque inner control arm bolts yet — they must be torqued at ride height.
9. 9

   Reconnect ball joint to knuckle
   Insert the ball joint stud into the knuckle taper. Install a NEW castle nut and torque to specification. Continue tightening (do not loosen) only as needed to align the castle slot with the stud hole, then install a NEW cotter pin and bend the legs per standard practice.
   ⚠Always use a new cotter pin. Never back off the nut to align the slot — only tighten further within spec.
   Torque spec

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

    Reconnect any disturbed wiring and brackets
    Reseat ABS sensor, brake wear sensor, and harness clips into their original brackets. Verify there is no contact between harness and rotating/moving suspension components through full travel.
11. 11

    Reinstall wheel
    Mount the wheel and hand-start all lug nuts. Snug evenly, then lower the vehicle until tires bear weight. Final torque comes after the vehicle is on the ground.
    Torque spec

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

    Final torque at ride height
    With the vehicle on the ground at normal ride height (re-pressurize air suspension via exiting Jack Mode after 12V is reconnected), torque the upper control arm inner bolts to specification. Suspension bushings must be loaded at ride height to prevent premature failure.
    ⚠Torquing control arm bolts with the suspension hanging will preload bushings and cause early failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reconnect the 12V (or 16V) low-voltage battery.
2. Power up the vehicle and allow the air suspension to self-level. Exit Jack Mode via the touchscreen.
3. Cycle the suspension through Low / Standard / High / Very High ride height settings and confirm normal operation with no faults.
4. Clear any chassis fault codes that may have set during 12V disconnect.
5. Verify steering wheel is centered; if not, an alignment is required.
6. Schedule a four-wheel alignment — any upper control arm or ball joint service on this chassis requires alignment to restore camber/caster.

Verification

• Test drive at low speed in a safe area: confirm no clunking, popping, or steering wander.
• Recheck castle nut cotter pin engagement and that legs are properly bent.
• Recheck wheel lug torque after 50 miles in a star pattern.
• Confirm air suspension raises and lowers normally through all ride heights without faults on the touchscreen.
• Have a four-wheel alignment performed and verify camber/caster/toe are within Tesla's published specifications for 2024 Model S Plaid.
• Note: while suspension is apart, this is a good opportunity to inspect the air struts — Plaid air struts commonly show wear by ~80K miles.

More procedures for this vehicle