Replace the front wheel bearing hub assembly on a 2024 Tesla Model S Plaid (tri-motor AWD). The front hub carries CV axle drive torque on this AWD vehicle, so the axle nut must be removed and properly re-torqued with a new retainer.

Warnings

Tools required

Parts

• Front wheel bearing hub assembly × 1 — Manufacturer-specified front hub assembly for 2024 Model S Plaid
• Axle nut (single-use) or new cotter pin/stake hardware × 1 — Per Tesla Service Manual — single-use fastener
• Hub mounting bolts (if specified single-use) × 4 — OEM specification — verify reusability

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 low-voltage battery in the frunk (under the nose cowl panel). Note: 2024 Plaid may use a 16V lithium auxiliary — verify location by VIN 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. Enable Jack Mode on the touchscreen (Controls > Service > Jack Mode) to disable air suspension self-leveling.
7. Loosen front wheel lug nuts while vehicle is on the ground.
8. Lift the front of the vehicle at Tesla-approved jack points using rubber pucks; support on rated jack stands.
9. Remove the front wheel.

Procedure

1. 1

   Remove axle nut
   Remove the axle nut retainer (cotter pin or stake) from the center of the front hub. Using a breaker bar and the correct axle nut socket, loosen and remove the axle nut. The axle nut is single-use and must be replaced.
   ⚠Do not use an impact gun to install the new axle nut later — only use a calibrated torque wrench.
2. 2

   Remove brake caliper and bracket
   Remove the front brake caliper bracket bolts and lift the caliper/bracket assembly off the rotor as a unit. Suspend the caliper from the strut or control arm with a hanger — do NOT let it hang by the brake hose. Remove the brake rotor (may require removing a small retaining screw or tapping the hat with a brass drift).
   ⚠Do not depress brake pedal while caliper is off — pistons can pop out.
3. 3

   Disconnect ABS sensor
   Locate the ABS/wheel speed sensor on the steering knuckle. Disconnect the harness clip and remove the ABS sensor retaining bolt. Carefully withdraw the sensor and set aside to avoid damage.
   ⚠ABS sensors are fragile — do not pry. If seized, apply penetrant and rotate gently before pulling.
   Torque spec

   ABS Sensor Bolt10 Nm (7 lb-ft)
4. 4

   Separate CV axle from hub
   With the axle nut removed, push the outer CV stub axle inward through the hub splines using a hub puller or by hand. If the axle is seized in the splines, use a brass drift on the stub end — never strike with steel. Support the axle with a wire to prevent it hanging on the inner joint.
5. 5

   Remove hub assembly from knuckle
   From the back side of the steering knuckle, locate and remove the wheel bearing hub mounting bolts. Steering may need to be turned to access all bolts. Once bolts are out, withdraw the hub assembly from the knuckle bore. If corroded in place, use a slide hammer with hub puller — do not pry against aluminum knuckle surfaces.
   ⚠Aluminum knuckle — do not strike or pry directly against the knuckle face.
   Torque spec

   Wheel Bearing Hub Bolts110 Nm (81 lb-ft)
6. 6

   Clean knuckle bore and mating surfaces
   Thoroughly wire-brush the knuckle bore and the bolt holes. Remove all corrosion and old threadlocker. Inspect the knuckle bore for damage or out-of-round condition. A clean, true mating surface is essential for proper bearing seating and no vibration.
7. 7

   Install new hub assembly
   Position the new hub assembly into the knuckle bore. Apply medium-strength threadlocker to the hub mounting bolt threads if specified by the OEM procedure. Install bolts hand-tight, then torque in a cross pattern to specification.
   Torque spec

   Wheel Bearing Hub Bolts110 Nm (81 lb-ft)
8. 8

   Reinstall CV axle through hub
   Slide the CV outer stub axle splines back through the new hub. Hand-thread the NEW axle nut to draw the axle into the hub — do not hammer. Snug the nut to hold the assembly together; final torque comes after the wheel is on the ground.
9. 9

   Reinstall ABS sensor
   Insert the ABS sensor into its bore in the knuckle. Install the retaining bolt and torque to specification. Reconnect the harness and ensure it is routed in the original clips, away from rotating components.
   Torque spec

   ABS Sensor Bolt10 Nm (7 lb-ft)
10. 10

    Reinstall rotor and caliper
    Install the brake rotor (with retaining screw if equipped). Position the caliper bracket over the rotor. Apply threadlocker to the caliper bracket bolts and torque to specification.
11. 11

    Final axle nut torque
    Reinstall the wheel and lug nuts hand-tight. Lower the vehicle so the wheel is loaded (or have an assistant apply the brake). Torque the new single-use axle nut to specification, then secure with a new cotter pin or stake the nut per OEM procedure.
    ⚠️An under- or over-torqued axle nut can cause bearing failure or hub separation. Always use a calibrated torque wrench and a NEW retainer.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
12. 12

    Torque lug nuts
    With the vehicle weight on the wheel, torque the lug nuts in a star pattern to specification.

Reassembly

1. Lower vehicle fully and remove jack stands.
2. Exit Jack Mode via the touchscreen and allow the air suspension to re-level.
3. Reconnect the low-voltage battery in the frunk.
4. Pump the brake pedal several times before driving to seat the caliper pistons against the pads.
5. Re-check lug nut torque after the first 50 miles of driving.

Verification

• Test drive at low speed first, listening for grinding, humming, or roar that changes with cornering load — indicates incorrect bearing preload or contaminated bearing.
• Verify no ABS, traction control, or stability control warnings on the touchscreen. The 2024 Model S may require a brief drive cycle for the ABS sensor to re-baseline; if a fault persists, a Tesla service center scan tool may be required to clear codes.
• After test drive, re-check that the axle nut retainer (cotter pin or stake) is fully seated.
• Confirm air suspension self-levels correctly at all four corners after exiting Jack Mode.
• Re-torque lug nuts after 50 miles. Tesla recommends tire rotation every 6,250 miles — note current mileage for next rotation.

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