suspension

Upper Control Arm - Front

for 2024 Tesla Model X Long Range Dual Motor AWD · AWD

Difficulty

Advanced

Time

1.5 h

Tools

Steps

Replace the front upper control arm on a 2024 Tesla Model X. The Model X uses an aluminum-intensive front suspension with standard air suspension, so air suspension service mode and aluminum-safe handling are required.

Warnings

⚠️Air suspension can self-level unexpectedly. Place the vehicle in Jack Mode (Service > Suspension > Jack Mode) before lifting to disable auto-leveling. Failure to do so can cause the vehicle to drop or rise on the lift.

⚠️Do NOT touch, cut, or pierce any orange high-voltage cable. The HV battery is floor-mounted directly beneath the cabin.

⚠Model X front suspension components and subframe are largely aluminum. Do not strike with a steel hammer — use a dead-blow or rubber mallet to avoid cracking castings.

⚠Use only Tesla-approved jack pad locations. Lifting on the battery pack or pinch welds will cause expensive damage.

⚠Final torque on control arm pivot bolts MUST be done with the suspension loaded at ride height to avoid premature bushing failure.

ℹ️A wheel alignment is required after replacing any control arm. Camber and caster will be affected on the upper arm.

Tools required

Vehicle lift or jack with jack stands rated for Model X (~2,500 kg)Essential

Jack pad pucks (Tesla-approved lift pad adapters to protect battery)Essential

Metric socket set (10–22 mm)Essential

Metric combination wrench setEssential

Torx and Allen (hex) bit setEssential

Calibrated torque wrench (20–150 Nm range)Essential

Ball joint separator / pickle fork or tie-rod end pullerEssential

Dead-blow or rubber mallet (no steel hammer on aluminum)Essential

Penetrating oil

Wheel chocksEssential

Trim removal tools (for plastic clips/covers)

Parts

Front Upper Control Arm Assembly (Model X, 2024, side-specific if applicable) × 1 — Manufacturer-specified front upper control arm for 2024 Model X LR AWD
Ball joint castle nut / retainer (if single-use) × 1 — OEM replacement fastener as specified by Tesla Service Manual
Control arm pivot bolts (if specified single-use) × 2 — OEM replacement fasteners per service manual

Preparation

Park on level ground, place in P, engage parking brake.
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.
Disconnect the 12V low-voltage battery, located in the frunk (similar position to Model S). Follow the under-hood cover removal and negative-terminal-first procedure.
DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal.
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.
Before disconnecting 12V: enter the touchscreen and activate Jack Mode (Service > Suspension > Jack Mode) to disable air suspension auto-leveling.
Be aware of the Falcon Wing doors — keep them closed and clear of the lift arms; their sensors and harnesses can be damaged if the door cycles unexpectedly during service.
Chock the rear wheels.
Loosen the front wheel lug nuts while the vehicle is on the ground.
Lift the vehicle at Tesla-approved jack points using puck adapters and support on jack stands. Confirm the vehicle is stable before working underneath.

Procedure

1
Remove front wheel
Fully remove the lug nuts and pull the front wheel from the affected side. Set the wheel aside on its sidewall to protect the finish.
2
Inspect and document
Photograph the existing upper control arm orientation, bushing alignment, and any factory paint marks on bolt heads. Note the routing of any wheel speed sensor or brake hose clips attached to the arm.
3
Support the lower control arm / knuckle
Place a jack under the lower control arm or knuckle to support suspension load. This prevents the strut/knuckle from dropping when the upper ball joint is released and keeps the air spring from extending unloaded.
⚠Do not let the knuckle hang on the brake hose or wheel speed sensor wiring.
4
Disconnect any sensor/harness clips on the upper arm
Release any wiring harness retainers or brake line clips from the upper control arm. Set them aside without stressing the wires.
5
Separate the upper ball joint from the knuckle
Remove the upper ball joint nut. Using a manufacturer-appropriate ball joint separator, free the ball joint stud from the steering knuckle. Do not strike aluminum components with a steel hammer.
⚠Tesla front knuckles are aluminum — use a press-style separator rather than a pickle fork where possible to avoid cracking the boss.
Torque spec
Ball Joint Nut88 Nm (65 lb-ft)
6
Remove the upper control arm pivot bolts
Support the arm, then remove the inboard pivot bolts that secure the upper control arm to the body/frame mount. Note bolt orientation and any alignment cams or shims for reinstallation.
ℹ️If the vehicle has alignment cam bolts, mark their position before removal to retain a baseline alignment.
Torque spec
Control Arm Bolts165 Nm (122 lb-ft)
7
Remove the upper control arm
Maneuver the arm down and out of the vehicle. Compare the new arm to the old one for ball joint position, bushing orientation, and overall geometry before installation.
8
Install the new upper control arm
Position the new arm into its inboard mount and start the pivot bolts by hand. Insert the ball joint stud into the knuckle and start the ball joint nut by hand. Do not fully torque pivot bolts yet.
9
Torque the ball joint nut
Tighten the upper ball joint nut to the specified torque. Hold the stud with a hex key if it tries to spin.
Torque spec
Ball Joint Nut88 Nm (65 lb-ft)
10
Snug the inboard pivot bolts
Snug (do not final-torque) the inboard pivot bolts. Final torque must be applied with the suspension loaded at ride height.
⚠Torquing the pivot bolts with the suspension hanging will preload the bushings and dramatically shorten their life.
11
Reattach harness and brake line clips
Reseat any wiring or brake hose retainers onto the new arm in their original positions.

Reassembly

Reinstall the front wheel and snug the lug nuts.
Lower the vehicle so the full weight rests on the wheels at normal ride height.
With the vehicle weight on the wheels, final-torque the upper control arm inboard pivot bolts to the Control Arm Bolts specification.
Final-torque the wheel lug nuts in a star pattern to the Wheel Lug Nuts specification.
Reconnect the 12V low-voltage battery (positive first, then negative) and reinstall the frunk cover.
Power the vehicle on. Exit Jack Mode through the touchscreen and allow the air suspension to self-level.
Have the front-end alignment performed before returning the vehicle to service.

Verification

Confirm no warning messages on the instrument cluster, particularly air suspension or stability/ABS faults.
Test drive at low speed and listen for any clunks from the upper control arm area over bumps; a properly seated ball joint and correctly torqued pivot is silent.
Verify the air suspension raises/lowers normally through all height settings (Low, Standard, High, Very High where available) — abnormal behavior may indicate a damaged height sensor or harness during the repair.
Confirm steering returns to center and the vehicle tracks straight; if not, alignment is mandatory.
Perform a 4-wheel alignment and document camber/caster within Tesla specification.
Re-inspect torque on the upper ball joint nut and pivot bolts after the first 100–200 miles, as is good practice on critical suspension fasteners.
While the vehicle is in for this service, note Tesla's other interval items the owner may be due for: brake fluid every 2 years, cabin air filter every 2 years (3 years if HEPA-equipped with Bioweapon Defense Mode), tire rotation every ~6,250 mi, and front/rear gear oil per the current Tesla service recommendation.