Replacement of a front upper control arm on a 2024 Model Y Long Range AWD. The Model Y front suspension uses an aluminum upper control arm with an integrated ball joint; the arm is replaced as an assembly.

Warnings

Tools required

Parts

• Front Upper Control Arm assembly (with ball joint and bushings) × 1 — OEM Tesla Model Y front upper control arm — verify left vs right
• Ball joint cotter pin × 1 — New cotter pin — do not reuse
• Ball joint castle nut × 1 — Replace if damaged or stretched — manufacturer-specified

Preparation

1. Park on level ground, place in P, and engage the 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 under the front trunk / frunk area on 2024 Model Y — refer to service manual for exact access panel).
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. Loosen the front wheel lug nuts while the vehicle is on the ground.
7. Raise the front of the vehicle using Tesla-approved lift points and lift pucks. Support on jack stands rated for the Model Y curb weight.
8. Remove the front wheel on the affected side.
9. Confirm you have the correct left/right upper control arm before beginning disassembly.

Procedure

1. 1

   Inspect and document
   Inspect the upper control arm, ball joint boot, and bushings. Note the orientation of the arm and how the ball joint stud passes through the steering knuckle. Take photos for reference.
2. 2

   Support the steering knuckle
   Place a jack under the lower control arm or steering knuckle to support the assembly once the upper ball joint is released. This prevents the knuckle from hanging on the CV axle or brake line.
   ⚠Do not allow the knuckle to hang freely — this can damage the CV joint, ABS sensor wiring, or brake hose.
3. 3

   Remove the ball joint cotter pin and castle nut
   Straighten and remove the cotter pin from the upper ball joint stud. Loosen and remove the castle nut. Discard the cotter pin — a new one is required on reassembly.
4. 4

   Separate the upper ball joint from the steering knuckle
   Using a ball joint separator tool, release the tapered ball joint stud from the knuckle. Avoid pickle-fork tools if you intend to preserve the boot on a reused arm — for a replacement, this is not a concern. Carefully lower the knuckle away from the upper arm.
   ⚠Aluminum knuckle — do not pry aggressively or strike with a steel hammer.
5. 5

   Remove the inner control arm bolts
   Locate the two inner pivot bolts securing the upper control arm to the chassis bracket / shock tower area. Note bolt orientation and any alignment cams or washers. Loosen and remove both bolts and lift the arm out of the vehicle.
   ℹ️If the bolts pass through eccentric/cam alignment hardware, mark their position before removal to ease alignment.
6. 6

   Compare old and new arm
   Place the removed arm next to the new one. Verify ball joint orientation, bushing style, and overall length match. Confirm left/right correctness. Transfer any reusable hardware only if specified by the manufacturer.
7. 7

   Install the new upper control arm — inner pivot
   Position the new arm into the chassis bracket. Install the inner pivot bolts hand-tight only at this stage. Do NOT final-torque yet — bushings must be clamped at ride height.
   Torque spec

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

   Reconnect the ball joint to the knuckle
   Raise the steering knuckle and seat the ball joint stud into the knuckle taper. Install the castle nut and torque to specification. Align the castle nut slot with the cotter pin hole by tightening (never loosening) and install a NEW cotter pin. Bend the legs of the cotter pin to secure.
   ⚠️A loose or omitted cotter pin can result in ball joint separation and loss of steering control.
   Torque spec

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

   Reinstall the wheel
   Mount the front wheel and install the lug nuts hand-tight. Lower the vehicle until the tire just contacts the ground (or use scale ramps) so the suspension is loaded at ride height.
10. 10

    Final torque inner control arm bolts at ride height
    With the vehicle weight on the wheels (suspension at normal ride height), torque the inner control arm pivot bolts to specification. This is critical for correct bushing preload and long-term durability.
    ⚠Torquing these bolts with the suspension hanging will cause the bushings to be permanently loaded off-center and fail prematurely.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
11. 11

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

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Confirm cotter pin is installed and bent at the ball joint.
2. Reconnect the 12V low-voltage battery.
3. Close frunk and verify all access panels are secured.
4. Cycle the steering lock-to-lock with the vehicle stationary on the ground to confirm no binding or unusual noise.
5. Drive the vehicle a short distance at low speed and listen for clunks, squeaks, or steering pull.
6. Schedule a four-wheel alignment immediately — front upper control arm replacement disturbs camber and caster.

Verification

• Perform a full four-wheel alignment on Tesla-spec equipment. Camber, caster, and toe must be brought within Tesla's published tolerance for 2024 Model Y Long Range AWD.
• Re-inspect the cotter pin at the ball joint after alignment is complete.
• Re-torque the inner control arm bolts after the first 100 miles is good practice on aluminum suspension hardware.
• Verify no warning messages on the touchscreen after reconnecting 12V (e.g., TPMS, stability control init). Drive briefly above 15 mph to allow systems to recalibrate.
• Reminder: Tesla recommends tire rotation every 6,250 mi on Model Y due to high curb weight and instant torque — note the odometer reading at this service for the next rotation interval.
• If the 12V battery is the original AGM unit and the vehicle is approaching 3+ years of age, consider load-testing it while access is convenient.

More procedures for this vehicle