Replacement of an upper ball joint on a 2024 Model X Plaid front suspension. On Model X the upper ball joint is integrated into the upper control arm assembly — the ball joint is not serviced separately from the arm.

Warnings

Tools required

Parts

• Upper control arm assembly (includes upper ball joint) — front, side-specific × 1 — Tesla Model X (Refresh/Plaid) front upper control arm — confirm left/right by VIN at parts counter
• Cotter pin for ball joint castle nut × 1 — Manufacturer-specified cotter pin — new
• Steering knuckle pinch bolt (if disturbed) × 1 — Single-use pinch bolt — replace

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 (similar position to Model S). Follow the under-hood cover removal sequence and isolate the negative terminal.
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. Be aware of the Falcon Wing doors overhead if the vehicle is on a two-post lift — ensure they are fully closed and will not be operated during service.
7. On the touchscreen (before powering down), enable Jack Mode (Controls > Service > Jack Mode) to disable air suspension self-leveling.
8. Loosen front wheel lug nuts while the vehicle is on the ground, then raise the vehicle on the manufacturer-designated lift points using puck adapters and support on rated stands.
9. Remove the front wheel on the affected side.

Procedure

1. 1

   Inspect and document
   With the wheel off, inspect the upper ball joint for play, torn boot, and grease loss. Photograph the orientation of the upper control arm, any alignment cam markings, and the routing of the ABS/brake wear sensor harness near the upper arm. Confirm whether the ball joint is integrated into the arm (typical for Model X) — if so, plan to replace the entire upper control arm assembly.
2. 2

   Support the lower control arm
   Place a jack under the lower control arm spring seat area to support the suspension and prevent the knuckle from dropping when the upper ball joint is separated. Do NOT support under the air spring or HV pack.
   ⚠Allowing the knuckle to swing freely can damage the half-shaft inner CV, ABS sensor wire, and brake hose.
3. 3

   Disconnect sway bar end link (if it interferes)
   If the upper sway bar link nut blocks knuckle articulation, hold the link shaft with an Allen key and remove the nut. Swing the link out of the way.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
4. 4

   Remove cotter pin and loosen castle nut
   Straighten and remove the cotter pin from the upper ball joint stud. Loosen — but do not yet fully remove — the castle nut, leaving it threaded a few turns to retain the stud while breaking the taper.
5. 5

   Break the ball joint taper
   Using a proper ball joint separator (tie-rod style puller preferred), break the taper between the ball joint stud and the steering knuckle. Do not strike the aluminum knuckle with a hammer. Once the taper releases, fully remove the castle nut.
   ⚠Aluminum knuckle — pickle-fork use risks damaging the boot and the knuckle. Prefer a screw-type separator.
6. 6

   Separate the upper arm from the knuckle
   Carefully lift the upper arm clear of the knuckle. Tie the knuckle assembly to the strut or coil-over to prevent it from hanging on the brake hose or ABS wire.
7. 7

   Remove the upper control arm from the chassis
   Note the position of any alignment cams or shims. Remove the upper control arm inboard pivot bolts from the chassis bracket. Support the arm as the last fastener is removed and withdraw the arm. Refer to the Tesla Service Manual for inboard pivot torque — torque to OEM specification.
   ℹ️Mark the position of any alignment eccentrics before removal to ease pre-alignment setup.
8. 8

   Install new upper control arm
   Install the new upper control arm into the chassis bracket using the original (or new, if specified) hardware. Run fasteners in finger-tight; do not final-torque the inboard bushing bolts yet — bushing bolts are torqued at ride height.
9. 9

   Reconnect ball joint to knuckle
   Seat the new ball joint stud into the knuckle taper. Install the castle nut and torque to specification. Align the castle nut slot with the stud hole by tightening (never loosening) to the next slot, and install a NEW cotter pin. Bend the cotter pin legs to retain.
   ⚠️A missing or reused cotter pin can allow the ball joint to back off and cause loss of steering control.
   Torque spec

   Ball Joint Nut102 Nm (75 lb-ft)
10. 10

    Reconnect sway bar link
    If disconnected, reattach the sway bar end link, holding the shaft with an Allen key while torquing the nut.
    Torque spec

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

    Reinstall wheel and lower vehicle
    Reinstall the front wheel. Hand-snug lug nuts, then lower the vehicle so the suspension is loaded at normal ride height before final-torquing bushing bolts.
    Torque spec

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

    Final-torque control arm bushing bolts at ride height
    With the vehicle's full weight on the wheels (or on a drive-on alignment rack), final-torque the upper control arm inboard pivot bolts. Torquing bushings while unloaded will pre-stress the rubber and shorten bushing life.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
13. 13

    Final lug torque
    Torque the wheel lug nuts in a star pattern to specification.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reconnect the 12V battery in the frunk and reinstall the cover.
2. Power the vehicle on. Exit Jack Mode via the touchscreen and allow the air suspension to self-level. Verify no air suspension faults appear on the cluster.
3. Cycle the steering lock-to-lock with the vehicle stationary on a smooth surface to settle the suspension and check for binding or noise.

Verification

• Confirm there are no chassis, ABS, or air-suspension alerts on the touchscreen. Clear any transient codes with a scan tool if needed.
• Verify the new cotter pin is installed and bent — visually inspect from below.
• Perform a four-wheel alignment at the vehicle's specified ride height. Model X alignment must be done with air suspension at Standard ride height; verify camber, caster, and toe are within Tesla specification.
• Road test at low speed first, listening for clunks over bumps and checking for steering pull. Increase to highway speed only after low-speed verification.
• Re-inspect the ball joint boot and torque marks after the first 100 miles.
• While the vehicle is in for suspension service, this is a good opportunity to check brake fluid age (Tesla recommends replacement every 2 years) and cabin air filter age (every 3 years on Model X with HEPA/Bioweapon Defense).

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