Replacement of a front upper control arm on a 2024 Tesla Model X Plaid. The Model X uses a multi-link aluminum front suspension with standard air suspension; final torque on control arm bolts must be done with the suspension loaded.

Warnings

Tools required

Parts

• Front Upper Control Arm Assembly (Model X 2021+ refresh, includes ball joint and bushings) × 1 — Manufacturer-specified upper control arm for 2024 Model X Plaid
• Ball joint nut (replace if specified as single-use) × 1 — OEM-spec self-locking nut

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 (refer to under-hood access panel; remove cowl cover as required).
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 so the air suspension does not attempt to self-level. Confirm ride height is stable.
7. Loosen front wheel lug nuts while the vehicle is on the ground.
8. Lift the front of the vehicle at the manufacturer-specified jacking points and support on jack stands. Verify stability before going under the vehicle.
9. Remove the front wheel on the affected side.

Procedure

1. 1

   Inspect work area
   Visually confirm there are no orange HV cables, HV connectors, or coolant lines routed near the upper control arm work area. The front suspension area should be free of HV components, but verify before proceeding. Photograph the existing arm orientation and any alignment marks for reference.
   ⚠️If any orange cable is visible in the work area, stop and reassess — you may be in the wrong location.
2. 2

   Support the lower control arm / knuckle
   Place a jack with a rubber pad under the lower control arm or steering knuckle to support the suspension assembly during ball joint separation. This prevents the knuckle from dropping and damaging the CV axle, brake hose, or wheel speed sensor wiring once the upper ball joint is released.
3. 3

   Disconnect sway bar end link (if required for access)
   If the sway bar end link interferes with upper control arm removal on this side, loosen the upper sway bar link nut while holding the link shaft with an Allen key to prevent it from spinning. Set the link aside.
   Torque spec

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

   Separate the upper ball joint from the knuckle
   Remove the upper ball joint nut. Using a proper ball joint separator (not a pickle fork, which can damage the boot if the joint is being reused — but acceptable here since the arm is being replaced), separate the upper ball joint stud from the steering knuckle. Support the knuckle so it does not fall outward and stress the CV joint or brake hose.
   ⚠Do not let the knuckle hang by the brake hose or wheel speed sensor wiring.
   Torque spec

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

   Remove the inboard control arm bolts
   Locate the two inboard pivot bolts that secure the upper control arm to the chassis/sub-frame mounting points. Note the orientation of any cam/eccentric washers if present (these affect alignment) and mark their position before removal. Remove the bolts and withdraw the control arm from the vehicle.
   ⚠If eccentric alignment cams are present, alignment will be required after reassembly regardless of marking.
   Torque spec

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

   Compare old and new arms
   Lay the new upper control arm next to the removed unit. Confirm bushing orientation, ball joint stud length, and overall geometry match. Verify any handed (left/right) markings.
7. 7

   Install the new upper control arm — inboard side
   Position the new arm into its chassis mounts. Install the inboard pivot bolts hand-tight only at this stage. Reinstall any cam/eccentric washers in their original orientation. Final torque is performed later with the suspension loaded at ride height.
8. 8

   Connect the upper ball joint to the knuckle
   Insert the upper ball joint stud into the knuckle. Install the ball joint nut and torque to specification. If the nut spins with the stud, apply downward pressure on the arm or use the specified hex feature on the stud to hold it.
   Torque spec

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

   Reinstall sway bar end link (if disconnected)
   Reattach the sway bar end link to its mount, holding the link shaft with an Allen key while torquing the nut.
   Torque spec

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

    Reinstall wheel and lower vehicle
    Reinstall the front wheel and snug the lug nuts. Lower the vehicle so its full weight is on the wheels (suspension at normal ride height). This is required before final torquing of the control arm pivot bolts to set the bushings at neutral preload.
    ⚠Torquing rubber-bushed control arm bolts with the suspension hanging will preload the bushings and dramatically shorten their life.
    Torque spec

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

    Final torque control arm pivot bolts at ride height
    With the vehicle's full weight on the wheels and the air suspension at normal ride height, torque the inboard upper control arm pivot bolts to specification. Access may require working through the wheel well or under the front of the vehicle on a drive-on lift.
    Torque spec

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

    Final torque on lug nuts
    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 any covers removed for access.
2. Re-enter the vehicle with the key fob; the air suspension should re-initialize. Exit Jack Mode via the touchscreen if it does not clear automatically.
3. Allow the suspension to self-level to normal ride height before driving.
4. Clear any chassis or suspension fault codes that may have set during the 12V disconnect/reconnect cycle.

Verification

• Confirm no suspension, ABS, or stability control warnings on the instrument cluster after a short test drive.
• Verify the air suspension reaches and holds normal ride height; check for any leveling errors on the touchscreen.
• Drive at low speed and listen for clunks, binding, or steering pulls — any of these indicate incorrect torque sequence (bushings preloaded) or a loose fastener.
• Have a four-wheel alignment performed at a shop equipped for Tesla Model X. Camber and caster on the Model X front suspension are sensitive to upper control arm replacement, and ADAS/Autopilot calibration relies on correct alignment.
• Tesla service interval reminder unrelated to this job: brake fluid is recommended every 2 years, cabin air filter every 2 years (3 years if HEPA-equipped), and tire rotation every ~6,250 mi — review these while the vehicle is in the shop.

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