Replace upper and lower front ball joints on a 2024 Model X Plaid. On this generation, the upper ball joint is integral to the upper control arm (knuckle-pressed design), so component-level replacement typically requires replacing the affected control arm assembly. Air suspension must be disabled before lifting.

Warnings

Tools required

Parts

• Front upper control arm assembly (includes upper ball joint) — manufacturer-specified for Model X Refresh/Plaid × 2 — OEM Tesla front upper control arm, 2021+ Model X Refresh
• Front lower control arm assembly OR lower ball joint (depending on serviceability of the as-built part) × 2 — OEM Tesla front lower control arm or lower ball joint, 2021+ Model X Refresh
• Cotter pins for ball joint castle nuts × 4 — Manufacturer-specified size
• Steering knuckle pinch bolt (single-use) × 2 — OEM single-use pinch bolt

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 in the frunk (lift frunk carpet/access panel, remove negative terminal first).
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: enable Jack Mode via the touchscreen to prevent the air suspension from leveling on the lift. Confirm the suspension does not pump up after lifting.
7. Disable Falcon door operation via Controls > Service Mode (or physically restrain — falcon doors can articulate unexpectedly during lift movement).
8. Loosen front wheel lug nuts while vehicle is on the ground.
9. Lift the vehicle and support on appropriate lift pads at Tesla-designated lift points (puck locations marked on the rocker panel). Remove front wheels.

Procedure

1. 1

   Inspect and confirm replacement scope
   Inspect both upper and lower ball joints for play by levering the wheel/knuckle vertically and horizontally. On 2021+ Model X Refresh / Plaid, the upper ball joint is integral to the upper control arm — confirm whether your replacement parts are full control arms or serviceable ball joints, and plan accordingly. Photograph the as-built routing of brake lines, ABS sensor wiring, and any clips before disassembly.
2. 2

   Disconnect sway bar end link from lower control arm
   Hold the sway bar link inner shaft with an Allen/hex key and remove the nut. Swing the link upward out of the way. Do not let it hang by the brake hose.
   Torque spec

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

   Support and unload the steering knuckle
   Support the lower control arm with a transmission jack or pole jack at the spring/bushing area to keep tension off the ball joints during separation. Do not jack on the ball joint boot or on a sensor.
   ⚠Air suspension struts may extend when unloaded — keep hands clear of pinch points.
4. 4

   Disconnect ABS sensor and brake hose bracket
   Unclip the ABS wheel speed sensor harness and any brake hose retainers from the knuckle/control arms so they are not stressed when the knuckle is freed. Do NOT disconnect hydraulic brake lines.
5. 5

   Separate upper ball joint from steering knuckle
   Remove the cotter pin from the upper ball joint castle nut, then loosen the nut but leave it threaded on by a few turns to capture the joint. Separate the taper using a ball joint separator or tie-rod puller — do not strike the knuckle with a steel hammer. Once the taper releases, fully remove the nut and lift the knuckle clear of the upper ball joint stud.
   ⚠Aluminum knuckle — use a separator tool, not impact.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
6. 6

   Separate lower ball joint from steering knuckle
   Some Model X applications use a pinch-bolt design at the lower joint and others a castle-nut design. If pinch bolt: remove and discard the single-use pinch bolt, then pry the knuckle slot open slightly and lift it off the lower stud. If castle nut: remove cotter pin, loosen nut, separate taper with separator tool. With both joints free, swing the knuckle aside and support it (do not let it dangle by the halfshaft or brake hose).
   Torque spec

   Pinch Bolt61 Nm (45 lb-ft)

   Ball Joint Nut88 Nm (65 lb-ft)
7. 7

   Remove upper control arm (if upper joint is integral)
   Unbolt the upper control arm from its inboard mount(s) at the chassis/strut tower. Note any shims or alignment cams and mark their orientation. Remove the control arm assembly. If the upper joint is separately serviceable on your part variant, press out per manufacturer-specified procedure instead.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
8. 8

   Remove lower control arm (if lower joint is integral) or replace lower ball joint
   Unbolt the lower control arm from its inboard chassis mounts and remove. If the lower ball joint is separately serviceable, support the arm and press the joint out per manufacturer-specified service procedure. Discard old fasteners that are specified single-use.
   Torque spec

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

   Install new upper control arm / upper ball joint
   Position the new upper arm into its inboard mounts and start all bolts hand-tight. Do NOT final-torque inboard control arm bolts yet — these must be torqued at ride height. Insert the upper ball joint stud into the knuckle, install a new castle nut, and torque to spec, then advance only as needed to align the cotter pin slot. Install a new cotter pin and bend per the manufacturer-specified routing.
   ℹ️Use the 102 Nm spec when the joint uses a new cotter pin; use 88 Nm where applicable per the joint design. Verify which spec applies to the specific joint being installed.
   Torque spec

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

    Install new lower control arm / lower ball joint
    Position the new lower arm and start inboard bolts hand-tight (do NOT final-torque yet). Engage the lower ball joint with the knuckle. If pinch-bolt design: install a NEW single-use pinch bolt and torque to spec. If castle-nut design: torque the new castle nut to spec and install a new cotter pin.
    Torque spec

    Pinch Bolt61 Nm (45 lb-ft)

    Ball Joint Nut88 Nm (65 lb-ft)
11. 11

    Reconnect sway bar link, ABS sensor, and brake hose retainers
    Reattach the sway bar end link to the lower control arm, holding the link shaft with an Allen key while torquing the nut. Reseat the ABS harness and brake hose into their original clips/brackets. Verify nothing is pinched, kinked, or contacting a moving suspension surface.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
12. 12

    Reinstall wheels and lower vehicle to ride height
    Install front wheels, snug lug nuts, then lower vehicle so suspension carries full vehicle weight. Reconnect 12V battery (negative last) before exiting Jack Mode so the air suspension can re-level. Allow the air suspension to settle to normal ride height.
    Torque spec

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

    Final-torque control arm inboard bolts at ride height
    With the vehicle at normal ride height and weight on the wheels, final-torque the upper and lower control arm inboard bolts to spec. This prevents bushing pre-load that would cause premature failure. Torque the wheel lug nuts in a star pattern to final spec.
    ⚠Skipping the ride-height torque step will destroy the new bushings within months.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Confirm both cotter pins are installed and properly bent.
2. Confirm the new pinch bolt (if used) is installed and torqued.
3. Verify ABS sensor and brake hose are routed identically to factory and not under tension at full steering lock.
4. Exit Jack Mode via the touchscreen and confirm the air suspension reaches normal ride height on its own.
5. Clear any chassis fault codes generated during the 12V disconnect (some will self-clear after a drive cycle).
6. Perform a four-wheel alignment — mandatory after any control arm or ball joint service.

Verification

• With wheels off the ground, grasp the tire at 12 and 6 o'clock and check for vertical play — there should be none.
• Repeat at 9 and 3 o'clock to confirm no tie rod or knuckle play.
• Inspect ball joint boots for proper seating and absence of grease weepage.
• Test drive at low speed in a parking lot first: listen for clunks over bumps, check that the steering wheel is centered and the car tracks straight.
• Confirm air suspension cycles correctly through Low / Standard / High via the touchscreen.
• Verify no suspension or ABS warnings on the touchscreen after a short drive cycle.
• Schedule a four-wheel alignment immediately if not performed in-shop. Recheck ball joint nut torque and pinch bolt at 100 mi as a precaution.

More procedures for this vehicle