Replacement of a rear upper control arm on a 2024 Model X Plaid. The rear suspension on Model X uses a multi-link aluminum design with air suspension; the upper control arm bolts must be final-torqued at ride height to avoid premature bushing failure.

Warnings

Tools required

Parts

• Rear upper control arm assembly (manufacturer-specified for Model X Plaid) × 1 — Tesla OEM rear upper control arm — confirm against VIN
• Control arm pivot bolt(s) — single-use if specified by manufacturer × 1 — OEM specification
• Ball joint nut (if not reusable) × 1 — OEM specification

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 (remove frunk trim per service manual to access).
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 on the touchscreen (Controls > Service > Jack Mode) so the air suspension does not attempt to self-level.
7. Chock the front wheels.
8. Loosen the rear wheel lug nuts while the vehicle is still on the ground.
9. Raise the vehicle using Tesla-approved lift points (puck adapters required to avoid damaging rocker pinch welds and battery enclosure).
10. Support the rear with jack stands if not on a lift.
11. Remove the rear wheel on the affected side.

Procedure

1. 1

   Inspect and document
   Visually inspect the rear suspension assembly. Photograph the orientation of the upper control arm, any alignment cam markings, and the routing of nearby brake lines, ABS sensor wiring, and air suspension lines. Note the camber/toe cam position if equipped so the new arm can be installed close to the original setting.
2. 2

   Support the rear knuckle/upright
   Place a jack with a soft pad under the rear lower control arm or knuckle to support its weight. The air spring will be unloaded with the wheel off; supporting the knuckle prevents it from dropping when the upper arm is disconnected and prevents strain on the half-shaft, brake line, and air spring line.
   ⚠Do not lift the knuckle with enough force to compress the air spring or stretch the air line.
3. 3

   Disconnect adjacent components as needed for access
   If access requires it, disconnect the sway bar end link from the lower arm by holding the stud with an Allen key and removing the nut. Carefully unclip any wiring harness or air line retainers from the upper control arm. Do not allow components to hang by their wires or lines.
   Torque spec

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

   Release the upper control arm at the knuckle
   Depending on the configuration, the outboard end of the upper arm attaches to the knuckle either via a ball joint with a castle/pinch nut or via a through-bolt. Remove the retaining hardware. If a ball joint is used, separate it using a proper ball joint separator — do not strike the aluminum knuckle with a hammer.
   ⚠Aluminum knuckle — use a press-style separator, not a pickle fork driven with heavy blows.
   Torque spec

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

   Remove the inboard pivot bolt
   Locate the inboard pivot bolt(s) where the upper arm attaches to the rear subframe. Note the orientation of any alignment cams or eccentric washers and mark their position with a paint pen before loosening. Remove the bolt and withdraw the upper control arm from the vehicle.
   ℹ️If the bolt is specified as torque-to-yield or single-use by the manufacturer, replace it.
6. 6

   Compare old and new arm
   Lay the new control arm next to the removed unit. Confirm length, bushing orientation, ball joint taper direction, and any sensor brackets match. Transfer any reusable hardware or clips as required.
7. 7

   Install the new upper control arm
   Position the new arm and start the inboard pivot bolt by hand, with any alignment cams set to the marked starting position. Engage the outboard ball joint or through-bolt at the knuckle and start that fastener by hand as well. Do not fully torque yet.
8. 8

   Snug fasteners; reconnect ancillary items
   Snug the inboard and outboard upper arm fasteners enough to hold position but allow bushing rotation. Reconnect the sway bar end link and any wiring/air-line retainers removed for access.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
9. 9

   Torque the outboard ball joint
   Torque the upper ball joint nut to specification. If a cotter pin or retaining clip is used, install new hardware.
   Torque spec

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

    Reinstall the wheel
    Reinstall the rear wheel and snug the lug nuts in a star pattern. Final torque will be applied after the vehicle is on the ground.
    Torque spec

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

    Lower vehicle to ride height and final-torque control arm bolts
    Lower the vehicle so the suspension is fully loaded at normal ride height. With the wheels on the ground, final-torque the inboard control arm pivot bolt(s) to specification. This is critical — torquing under droop will damage the bushing.
    ⚠️Failure to final-torque at ride height will cause bushing failure within months and may compromise rear stability.
    Torque spec

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

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

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Confirm all suspension fasteners are torqued and any removed clips/retainers for wiring or air lines are reseated.
2. Reconnect the 12V battery in the frunk and reinstall any frunk trim removed for access.
3. Exit Jack Mode on the touchscreen (Controls > Service > Exit Jack Mode). Allow the air suspension to self-level before driving.
4. Verify there are no suspension or chassis warnings on the instrument cluster/touchscreen.

Verification

• With the vehicle at ride height, visually confirm the new upper control arm is centered in its travel and the bushing is not pre-loaded.
• Schedule a four-wheel alignment immediately — replacing a rear upper control arm changes camber and toe on this platform.
• Test drive at low speed first, listening for clunks over bumps; then at highway speed, checking for vibration, pulling, or off-center steering.
• Recheck the inboard control arm bolt torque after the first 100–200 miles as a precaution, as this fastener carries the full cornering load.
• While the vehicle is on the lift, take the opportunity to check Tesla's other interval items: brake fluid (every 2 years), cabin air filter (every 2 years, or 3 years if HEPA-equipped), and rear drive unit gear oil (Tesla now recommends service rather than treating it as lifetime fluid).

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