Replacement of a front upper control arm on a 2024 Model X Plaid. The Model X uses a multi-link aluminum front suspension with air suspension; care must be taken with aluminum components and air suspension calibration is recommended after the repair.

Warnings

Tools required

Parts

• Front Upper Control Arm Assembly (manufacturer-specified for 2024 Model X) × 1 — Refer to Tesla parts catalog for 2024 Model X Plaid front upper control arm
• Ball joint nut (single-use, if specified by Tesla) × 1 — OEM replacement fastener
• Control arm pivot bolts (replace if specified as single-use) × 2 — OEM replacement fasteners

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Exit ALL doors with 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). Remove frunk liner and disconnect 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: enter the touchscreen Service menu and enable Jack Mode / Transport Mode to lock air suspension at the current ride height.
7. Loosen front wheel lug nuts while tires are on the ground.
8. Lift front of vehicle at factory aluminum jack points only and support on rated jack stands. Confirm the air suspension does not attempt to compensate.
9. Remove the affected front wheel.

Procedure

1. 1

   Inspect and photograph
   Photograph the existing upper control arm orientation, ball joint stud direction, and any alignment cam markings on the inner pivot bolts. This reference will help reinstallation and minimize alignment drift.
2. 2

   Disconnect sway bar end link (if access requires)
   If the sway bar end link interferes with knuckle articulation needed to free the upper ball joint, unbolt the upper end link nut. Hold the stud shaft with an Allen key to prevent spinning.
   Torque spec

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

   Separate upper ball joint from steering knuckle
   Remove the cotter/retainer if equipped, then loosen the upper ball joint nut. Back the nut off so it sits flush with the stud end (protects threads). Use a proper ball joint separator to break the taper. Do NOT use a pickle fork that will damage the boot if the joint is being reused; here it is being replaced so a fork is acceptable. Once free, fully remove the nut.
   ⚠Support the knuckle/hub assembly with a strap or stand so it does not fall outward and stress the half-shaft inner CV joint or the brake hose.
   Torque spec

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

   Mark inner pivot bolt position
   If the upper control arm uses cam-style alignment bolts at the chassis pivot, mark the cam position with a paint pen before removal to preserve approximate camber/caster setting. Note: a four-wheel alignment is still required after the job.
5. 5

   Remove inner pivot bolts
   Support the control arm with one hand, then remove the inner pivot bolts/nuts that secure the upper control arm to the chassis bracket. Withdraw the arm downward and outward, clearing any wiring or sensor harnesses routed nearby.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Compare new vs. old arm
   Place the new upper control arm next to the old one and verify length, ball joint orientation, and bushing geometry match exactly. Confirm side-specific (left vs. right) labeling. Verify the new ball joint stud taper matches the knuckle bore.
7. 7

   Install new upper control arm to chassis
   Position the new arm into the chassis bracket. Insert the pivot bolts in the same direction as the originals, with cam washers (if equipped) aligned to your reference marks. Hand-thread the nuts. DO NOT final-torque yet — these must be torqued at ride height.
8. 8

   Reconnect ball joint to knuckle
   Lift the knuckle to engage the upper ball joint stud into the knuckle taper. Install the ball joint nut and torque to specification. Install new cotter pin or retainer if applicable.
   ⚠Never back off the ball joint nut to align a cotter pin hole — only tighten further to the next slot, or the joint will not be properly preloaded.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
9. 9

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

   Sway Bar Link Nuts55 Nm (41 lb-ft)
10. 10

    Reinstall wheel and lower vehicle to ride height
    Mount the front wheel and snug the lug nuts. Lower the vehicle so the suspension carries full vehicle weight on the wheels. Use drive-on ramps or wheel cribs if you need underbody access while loaded.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
11. 11

    Final-torque inner pivot bolts at ride height
    With the vehicle weight on the wheels and suspension at normal ride height, final-torque the upper control arm inner pivot bolts to specification. This prevents bushing preload that would cause early failure.
    ⚠Skipping ride-height torque is the #1 cause of premature bushing failure on Tesla control arms. Do not omit this step.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
12. 12

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

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reinstall any underbody panels or splash shields removed for access. Torque to OEM specification — refer to Tesla Service Manual.
2. Reconnect the 12V battery (negative last). Reinstall frunk liner.
3. Allow the vehicle to wake fully; the air suspension will self-level. Verify no error messages on the touchscreen.
4. Disable Jack Mode if it remained active.
5. Drive the vehicle a short distance at low speed to a four-wheel alignment shop — do not drive at highway speed before alignment is corrected.

Verification

• Confirm no suspension, ABS, or stability control warnings on the touchscreen after a key cycle and short drive.
• Have a four-wheel alignment performed — mandatory after any front suspension component replacement on a Model X.
• After alignment, verify ride height is even side-to-side. If uneven, perform an air suspension ride-height calibration via Service Mode (or have a Tesla-certified technician do so).
• Road test at low speed first, listening for clunks over bumps (indicates loose pivot bolt or unseated ball joint) and checking for steering pull.
• Re-inspect ball joint nut and inner pivot bolts after ~100 miles to confirm torque retention.
• While the vehicle is in for this service, note Tesla's actual maintenance intervals: brake fluid every 2 years, cabin air filter every 2 years (3 years for HEPA-equipped X), and battery coolant inspection at 4 years / 50,000 mi. Tire rotation every 6,250 mi is especially important on Plaid trim due to instant torque wear.

More procedures for this vehicle