Replacement of an upper ball joint on a 2024 Model X Long Range. On the Model X, the upper ball joint is integrated into the upper control arm assembly — the ball joint is not serviced separately, the entire upper control arm is replaced.

Warnings

Tools required

Parts

• Upper Control Arm Assembly (ball joint integrated) — front, side-specific × 1 — Tesla Model X (2021+ refresh) front upper control arm — confirm left/right via VIN at parts counter
• New cotter pin for ball joint castle nut × 1 — OEM-spec cotter pin matching ball joint stud
• New steering knuckle pinch bolt (if disturbed) × 1 — OEM-spec single-use pinch bolt

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. Open the frunk and disconnect the 12V low-voltage battery (negative terminal first). The 12V battery is located in the frunk area on the Model X.
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, enter Jack Mode on the touchscreen (Controls > Service > Jack Mode) to disable air suspension self-leveling. Note: Jack Mode is lost when 12V is disconnected — once disconnected, the suspension will hold its current height but will not actively level.
7. Loosen the front wheel lug nuts on the affected side while the vehicle is on the ground.
8. Raise the front of the vehicle at the manufacturer-specified jack points and support on rated jack stands. Verify stability before going under the vehicle.
9. Remove the front wheel on the affected side.

Procedure

1. 1

   Inspect and document
   Photograph the upper control arm, ball joint stud orientation, and any alignment shim/cam markings. Note the position of the upper strut tower nuts for reference. Confirm the failure mode (torn boot, play, clunk) before proceeding.
2. 2

   Support the lower control arm
   Place a floor jack under the lower control arm to support the spring/strut load and keep the knuckle stable while the upper joint is separated. Apply only light upward pressure — do not lift the vehicle off the stands.
   ⚠The lower control arm is under spring/air-strut preload. Releasing the upper joint without supporting the knuckle can allow the assembly to drop suddenly.
3. 3

   Disconnect the upper ball joint from the steering knuckle
   Remove the cotter pin from the upper ball joint castle nut and discard it. Loosen the castle nut but leave it threaded on the stud by a few threads to capture the joint. Use a ball joint separator to break the taper between the ball joint stud and the upper knuckle eye. Once separated, fully remove the nut and lift the knuckle clear of the stud.
   ⚠Do not hammer the knuckle. Use a proper separator tool to avoid damaging the aluminum knuckle and the wheel speed sensor.
   Torque spec

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

   Remove the upper control arm from the chassis
   Locate and remove the upper control arm-to-chassis fasteners at the strut tower / shock tower mounting area. Note the orientation of any alignment cams or shims and mark them so they can be reinstalled in the same position to preserve alignment as closely as possible. Remove the upper control arm assembly from the vehicle.
   ℹ️If the upper arm uses cam-style alignment bolts, scribe a reference line across the cam and the bracket before removal to aid reassembly.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
5. 5

   Compare old and new arms
   Lay the new upper control arm next to the old one. Verify length, ball joint stud orientation, bushing geometry, and that side (L/R) is correct. Confirm the new ball joint boot is intact and the stud is greased per the manufacturer-specified condition.
6. 6

   Install the new upper control arm to the chassis
   Position the new upper control arm into the chassis brackets. Install the chassis-side fasteners and any alignment cams in the marked positions. Snug only — final torque is set after the suspension is loaded at ride height.
7. 7

   Reconnect the ball joint to the steering knuckle
   Guide the new ball joint stud into the upper knuckle eye. Install the castle nut. Torque the ball joint nut to specification, then continue tightening only as far as needed to align the next slot with the stud's cotter pin hole — never back off to align. Install a NEW cotter pin and bend the legs to retain.
   ⚠️Two torque specs exist for the ball joint nut depending on configuration: 88 Nm (65 lb-ft) and 102 Nm (75 lb-ft) with new cotter pin. Confirm the correct value for this exact joint against current Tesla service information before final torque.
   Torque spec

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

   Reinstall any disturbed components
   If the strut/shock upper mount, sway bar end link, or steering knuckle pinch bolt was disturbed during separation, reinstall them now. Use a new pinch bolt if removed. Hold the sway bar link shaft with an Allen key to prevent spinning while torquing the nut.
   Torque spec

   Pinch Bolt61 Nm (45 lb-ft)

   Sway Bar Link Nuts55 Nm (41 lb-ft)

   Strut Tower Nuts50 Nm (37 lb-ft)

Reassembly

1. Reinstall the front wheel and snug the lug nuts.
2. Lower the vehicle so full vehicle weight is on the wheels before final torque on the chassis-side control arm fasteners.
3. With the vehicle at ride height, final-torque the upper control arm chassis bolts. Note: the verified 165 Nm / 122 lb-ft 'Control Arm Bolts' spec is to be applied with vehicle weight on the wheels — confirm this value applies to the upper arm on this specific vehicle; if Tesla service data lists a different value for the upper arm, torque to OEM specification — refer to Tesla Service Manual.
4. Final-torque the wheel lug nuts in a star pattern.
5. Reconnect the 12V battery (negative last). Close the frunk.
6. Re-enter the vehicle. Allow the air suspension to re-initialize and self-level. Cycle through ride heights once on the touchscreen (Low / Standard / High) to confirm normal operation.

Verification

• Confirm no warning messages on the instrument cluster related to suspension, ABS, or stability control.
• Check for clunks or play by gently rocking the wheel at 12 and 6 o'clock positions — there should be zero detectable play at the upper joint.
• Inspect the new ball joint boot for damage or pinching.
• Verify the cotter pin is installed and bent over.
• Drive the vehicle at low speed and confirm no clunks over bumps and that the steering tracks straight (mild pull is expected until alignment is performed).
• Schedule a 4-wheel alignment immediately — upper control arm replacement directly affects camber and caster on the Model X.
• While under the vehicle, take advantage of access to inspect the front drive unit fluid service interval (Tesla now recommends gear oil service ~12,500 mi initial, then 25,000–50,000 mi) and brake fluid age (Tesla recommends every 2 years). Note these for the owner if due.
• Re-check ride height on all four corners after a short drive — confirm the air suspension is leveling correctly and not throwing a fault.

More procedures for this vehicle