Replacement of a front upper control arm on a 2024 Model Y Long Range AWD. The Model Y front suspension uses a multi-link aluminum design shared with the Model 3 platform; care must be taken not to damage aluminum components or strip threaded fasteners.

Warnings

Tools required

Parts

• Front Upper Control Arm Assembly (left or right as applicable) × 1 — OEM Tesla Model Y front upper control arm — confirm side and revision against VIN
• Ball joint castle nut cotter pin × 1 — New cotter pin — single-use

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 behind/under the rear seat area on 2024 Model Y — refer to vehicle-specific 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. Place wheel chocks at the rear wheels.
7. Loosen the front wheel lug nuts on the affected side while the vehicle is still on the ground.
8. Raise the front of the vehicle using Tesla-approved lift points and pucks; support securely on jack stands.
9. Confirm the vehicle is set to 'Jack Mode' via the touchscreen if available (Service > Jack Mode) to prevent self-leveling activity — note: 2024 Model Y has coil suspension, so this is primarily to disable any active systems.
10. Remove the front wheel on the affected side.
11. Inspect the new control arm against the old one for correct fitment, ball joint orientation, and bushing alignment before installation.

Procedure

1. 1

   Access and inspect the upper control arm
   With the wheel removed, locate the upper control arm at the top of the strut/knuckle assembly. Inspect the inboard bushing mounts (at the shock tower / upper frame) and the outboard ball joint at the steering knuckle. Note routing of any wiring (ABS, brake wear sensor) clipped to the arm.
2. 2

   Release any clipped wiring or lines
   Carefully unclip any ABS sensor harness or brake hose retainers attached to the upper control arm using a plastic trim tool. Do not pull on wiring — release the clip first.
   ⚠Damaged ABS harnesses will throw fault codes and disable Autopilot/traction control until repaired.
3. 3

   Remove the ball joint cotter pin and loosen the castle nut
   Straighten and remove the cotter pin from the upper ball joint stud at the steering knuckle. Loosen the castle nut but leave it threaded on the stud by a few turns to prevent the joint from snapping free uncontrolled.
   ⚠Cotter pins are single-use. Have a new cotter pin ready before reassembly.
4. 4

   Separate the upper ball joint from the knuckle
   Using a tie-rod / ball joint separator tool, break the taper between the upper ball joint stud and the steering knuckle. Avoid striking the knuckle or arm directly with a steel hammer. Once free, fully remove the castle nut and lift the ball joint stud out of the knuckle.
   ⚠Aluminum knuckle — do not pry aggressively or strike with steel; use a proper separator tool.
5. 5

   Support the knuckle
   Use a bungee cord or wire to suspend the steering knuckle/strut so it does not hang on the brake hose or ABS wiring while the upper arm is removed.
6. 6

   Remove the inboard control arm bolts
   Identify and remove the inboard mounting bolts/nuts securing the upper control arm to the chassis/shock tower. Note orientation of any cam bolts or alignment markers — mark their position with a paint pen before removal to aid rough alignment on reinstall (a final alignment is still required).
   ℹ️If the inboard fasteners are eccentric/cam-style alignment bolts, photographing their position before removal can save alignment time.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
7. 7

   Remove the upper control arm
   Maneuver the old upper control arm out of the vehicle. Compare it side-by-side with the replacement to confirm correct length, bushing style, and ball joint orientation.
8. 8

   Install the new upper control arm — inboard side
   Position the new upper control arm into the chassis brackets. Hand-thread the inboard bolts/nuts (with cam bolts in their previously marked positions if applicable). Do NOT final-torque yet — bushings must be tightened at ride height.
9. 9

   Install the ball joint into the knuckle
   Lower the upper ball joint stud into the steering knuckle taper. Install the castle nut and torque the ball joint nut to specification, then continue tightening (only) until the slot aligns with the cotter pin hole. Install a new cotter pin and bend its legs to lock.
   ⚠Never back off the castle nut to align the cotter pin slot — only tighten further within the allowable range.
   Torque spec

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

    Reattach wiring and hoses
    Reclip the ABS harness, brake hose, and any other retainers to the new upper control arm in their original positions. Confirm no pinching or chafing through the full steering range.
11. 11

    Reinstall the wheel
    Mount the front wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground but full vehicle weight is not yet on the suspension.
12. 12

    Lower vehicle to ride height and final-torque inboard control arm bolts
    Lower the vehicle fully to the ground so the suspension is loaded at normal ride height. Torque the inboard upper control arm bolts to specification. This step prevents premature bushing wear from being clamped at the wrong angle.
    ⚠Final-torquing control arm bushings while the wheel is hanging will twist the bushing in service and shorten its life.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
13. 13

    Final-torque lug nuts
    With the vehicle on the ground, 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 low-voltage battery and reinstall any access trim.
2. Power on the vehicle and verify no chassis, ABS, or stability control warnings are displayed on the touchscreen.
3. Cycle the steering lock-to-lock with the vehicle stationary on the ground to verify free movement and no contact between the new arm and surrounding components.
4. Schedule and perform a 4-wheel alignment immediately — do not return the vehicle to normal use without alignment.
5. After alignment, perform an Autopilot/camera recalibration drive as prompted by the vehicle (the Model Y typically auto-calibrates over a short driving distance with clear lane markings).

Verification

• Confirm steering wheel is centered and the vehicle tracks straight after alignment.
• Listen for clunks or rattles over bumps — a properly installed upper control arm should be silent.
• Re-inspect the cotter pin at the upper ball joint after the test drive to confirm it is fully seated and locked.
• Recheck control arm bolt and ball joint nut torque after the first ~100 miles of driving.
• Tesla recommends tire rotation every 6,250 miles on Model Y due to high tire wear — note current mileage and schedule the next rotation.
• While the vehicle is up, this is also a good time to check brake fluid age (Tesla recommends replacement every 2 years) and cabin air filter age (every 2 years).

More procedures for this vehicle