Replace the front upper control arm bushing on a 2024 Model X. On this generation, Tesla supplies the upper control arm as a complete assembly — the bushing is not serviced separately, so this procedure covers replacing the upper control arm to address a worn bushing.

Warnings

Tools required

Parts

• Front upper control arm assembly (bushing not serviced separately) × 1 — Tesla Model X (2021+ refresh) front upper control arm — refer to VIN-specific Tesla parts catalog
• Ball joint cotter pin × 1 — OEM-spec cotter pin — single use

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 12V low-voltage battery, located in the frunk on Model X (similar position to Model S). Refer to the access panel/cover under the frunk liner.
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 the 12V, enter Jack Mode on the touchscreen to disable air suspension self-leveling.
7. Loosen the front wheel lug nuts while the vehicle is still on the ground.
8. Lift the vehicle using ONLY the factory jack pad points and support on rated stands. Confirm the vehicle is stable before going underneath.
9. Remove the front wheel on the affected side.
10. Inspect surrounding components — note routing of any wheel speed sensor harnesses, brake hose clips, and ride height sensor linkage.

Procedure

1. 1

   Disconnect ride height sensor (if on affected side)
   If the front ride height sensor link attaches to the lower control arm or knuckle on the side being serviced, carefully unclip it. The sensor arm is plastic and brittle — do not pry. Set it aside so it cannot be bent or damaged during suspension movement.
   ⚠A damaged ride height sensor will trigger air suspension faults and require Tesla service software to recalibrate.
2. 2

   Disconnect sway bar end link
   Locate the front sway bar end link at the strut/lower arm. Hold the ball stud with an Allen key while loosening the nut. Disconnect the link to free up suspension travel.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
3. 3

   Support the lower control arm
   Place a floor jack under the lower control arm, near the ball joint, and apply light upward pressure. This supports the knuckle and prevents the strut/spring assembly from dropping when the upper ball joint is separated.
   ⚠Do not jack on the air strut body. Support the lower control arm only.
4. 4

   Separate the upper ball joint from the knuckle
   Remove the cotter pin from the upper ball joint stud, then loosen (but do not fully remove) the ball joint nut. Use a press-style ball joint separator to break the taper. Once free, remove the nut and lower the knuckle slightly. Discard the cotter pin.
   ⚠Do not use a pickle fork in a way that damages the ball joint boot of any component you intend to reuse. The upper ball joint is being replaced as part of the arm assembly, so damage to its boot is acceptable.
   Torque spec

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

   Disconnect upper strut tower (if required for clearance)
   On Model X, the upper control arm inner pivot bolts are accessed from above through the strut tower area. If clearance is insufficient, loosen — do NOT fully remove unless required — the strut tower nuts to gain access. Support the strut from below if you fully remove the nuts.
   ⚠Air suspension struts are pressurized. Do not attempt to disassemble the strut. Treat as a sealed assembly.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
6. 6

   Remove upper control arm pivot bolts
   Locate the inner pivot bolts that secure the upper control arm to the chassis bracket. Mark or photograph the orientation of any cam/eccentric washers (alignment adjustment hardware). Remove the bolts and withdraw the upper control arm from the vehicle.
   ℹ️Note the orientation of alignment cams. Even though an alignment will be performed, restoring approximate position helps the vehicle drive safely to the alignment shop.
   Torque spec

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

   Inspect the failed bushing and surrounding components
   Inspect the removed arm and confirm bushing failure (cracking, separation, voids). Inspect the chassis mounting bracket for elongation or damage. Inspect the upper ball joint boot — if you intended to reuse the arm and only the bushing was bad, stop here: Tesla supplies this arm as an assembly and the bushing is not serviced individually. Replace the complete arm.
   ℹ️If the chassis bracket is damaged, this becomes a body-shop repair. Do not attempt to weld or straighten suspension mounts.
8. 8

   Install the new upper control arm
   Position the new control arm assembly into the chassis bracket. Install the inner pivot bolts with any cam/eccentric washers in their original orientation. Hand-tighten only at this stage — final torque is applied at ride height.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
9. 9

   Reconnect the upper ball joint to the knuckle
   Raise the lower control arm jack to align the new upper ball joint stud into the knuckle. Install a NEW ball joint nut and torque to specification. Install a new cotter pin — if the slots don't align, tighten further (never loosen) to align.
   Torque spec

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

    Reconnect strut tower (if loosened) and sway bar link
    If strut tower nuts were loosened or removed, torque to specification. Reconnect the sway bar end link, holding the stud shaft with an Allen key while torquing the nut.
    Torque spec

    Strut Tower Nuts50 Nm (37 lb-ft)

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

    Reconnect ride height sensor
    Reattach the ride height sensor link to its mounting point. Verify it moves freely through full suspension travel without binding.
12. 12

    Reinstall wheel and lower vehicle
    Mount the wheel and snug the lug nuts. Lower the vehicle until tires touch the ground but full weight is not yet on suspension; final-torque lug nuts in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
13. 13

    Final-torque control arm pivot bolts at ride height
    Lower the vehicle fully to the ground (or load suspension to simulated ride height on a drive-on lift). With suspension loaded, final-torque the upper control arm pivot bolts to specification. This prevents the new bushing from being preloaded in a twisted state, which causes premature failure.
    ⚠️Skipping the load-at-ride-height torque step will destroy the new bushing within months. This is the single most common cause of repeat failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Confirm all fasteners are torqued and the cotter pin is installed on the ball joint nut.
2. Reconnect the 12V battery in the frunk and reinstall any covers.
3. Close the frunk and verify all doors (including falcon doors) operate normally.
4. Power on the vehicle and exit Jack Mode. The air suspension will re-level — observe for normal behavior on both sides.
5. Clear any suspension or ride-height-related alerts on the touchscreen. If alerts persist, a Tesla service center diagnostic may be needed.

Verification

• With the vehicle at normal ride height, visually confirm both front corners sit at equal height — air suspension should self-level within 30 seconds of power-on.
• Test drive at low speed first; listen for clunks, squeaks, or knocks from the front suspension over bumps.
• Verify the steering wheel is centered and the vehicle tracks straight. Any pull or off-center steering must be corrected at alignment.
• Schedule a four-wheel alignment immediately — Model X is highly sensitive to camber/caster changes after upper arm service.
• Check the touchscreen for any chassis, suspension, or ride-height fault codes.
• Note for the owner: while you are under the vehicle, this is also an opportunity to inspect brake fluid age (Tesla recommends replacement every 2 years) and verify the cabin air filter service interval (every 2 years, or every 3 years for HEPA-equipped Model X with bioweapon defense mode).

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