Replacement of a front upper ball joint on a 2024 Model Y Performance AWD. On this platform the upper ball joint is integral to the upper control arm assembly — the ball joint is not serviced separately from the arm.

Warnings

Tools required

Parts

• Upper control arm assembly with integrated upper ball joint (manufacturer-specified for 2024 Model Y Performance) × 1 — OEM Tesla front upper control arm — confirm by VIN
• Cotter pin for ball joint castellated nut × 1 — OEM-spec cotter pin
• Steering knuckle pinch bolt (single-use) × 1 — OEM-spec single-use pinch bolt

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 behind/under the rear seat area on 2024 Model Y — consult vehicle for exact access). Follow Tesla's documented disconnect sequence.
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 the vehicle in 'Jack Mode' via the touchscreen (Service menu) to disable automatic air/level functions and prevent unintended motion — note: 2024 Model Y uses coil suspension, but Jack Mode still suppresses systems that can interfere.
7. Loosen the front wheel lug nuts while the vehicle is on the ground.
8. Raise the front of the vehicle using Tesla-approved lift points and pucks; support securely on jack stands.
9. Remove the front wheel on the affected side.
10. Inspect the upper control arm, ball joint boot, and surrounding components for additional damage before proceeding.

Procedure

1. 1

   Support the steering knuckle
   Place a jack stand or floor jack with a wood block under the lower control arm/knuckle to support the assembly once the upper ball joint is released. This prevents the knuckle from falling and stressing the brake hose, ABS wire, and CV axle.
2. 2

   Disconnect the front sway bar end link (if required for clearance)
   If access to the upper control arm is restricted, remove the upper sway bar end-link nut. Hold the stud with an Allen key while loosening the nut to prevent the stud from spinning. Set the link aside.
   Torque spec

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

   Remove the cotter pin and loosen the upper ball joint nut
   Straighten and remove the cotter pin from the upper ball joint castellated nut. Loosen the ball joint nut but do not fully remove it yet — back it off until the top of the nut is flush with the threaded stud. This protects the threads and prevents the knuckle from dropping uncontrolled when the joint releases.
   ⚠Discard the cotter pin. Always install a new cotter pin on reassembly.
4. 4

   Separate the upper ball joint from the steering knuckle
   Use a proper ball joint separator tool to break the taper. Avoid pickle-fork tools if possible, as they will destroy the boot — acceptable here only because the entire arm is being replaced. Do NOT strike the aluminum knuckle directly. Once the taper releases, fully remove the ball joint nut.
   ⚠Aluminum knuckle — do not hammer directly. Use the separator tool.
5. 5

   Swing the knuckle outward and support
   Carefully tilt the steering knuckle outward to clear the upper ball joint stud. Ensure the brake hose, ABS sensor wire, and CV axle are not stressed. Support the knuckle so it cannot swing freely.
6. 6

   Remove the upper control arm chassis bolts
   Remove the bolts/nuts securing the upper control arm to the chassis/frame mounting points. Note the orientation of any cam/eccentric washers used for alignment — mark their position before removal so the new arm can be installed in the same approximate alignment setting (final alignment must still be performed at a shop).
   ℹ️If the upper arm uses alignment cams, mark them with paint before removal to provide a starting reference.
7. 7

   Remove the upper control arm assembly
   Maneuver the upper control arm out of the chassis and away from the vehicle. Inspect the chassis mounting points and bushing pockets for damage or corrosion.
8. 8

   Install the new upper control arm assembly
   Position the new upper control arm into the chassis mounts. Hand-thread the chassis bolts with any cam/eccentric hardware aligned to the marks made during removal. Do not final-torque the chassis bolts yet — they must be torqued with vehicle weight on the wheels.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
9. 9

   Reconnect the upper ball joint to the knuckle
   Guide the upper ball joint stud into the steering knuckle taper. Install the castellated nut and tighten to the initial specification, then continue tightening (do not back off) only as needed to align the next castellation slot with the cotter pin hole. Install a NEW cotter pin and bend the legs to secure.
   ⚠Use the higher torque value (102 Nm / 75 lb-ft) only if required to align the cotter pin hole — never loosen the nut to align the slot.
   Torque spec

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

    Reinstall the sway bar end link (if removed)
    Reinstall the sway bar end-link nut, holding the stud with an Allen key to prevent rotation. Torque to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
11. 11

    Inspect related hardware
    Verify the steering knuckle pinch bolt (if disturbed during knuckle articulation) and any other fasteners are properly seated. If the lower pinch bolt was disturbed, replace it with a new single-use bolt and torque to specification.
    Torque spec

    Pinch Bolt61 Nm (45 lb-ft)

Reassembly

1. Reinstall the front wheel and hand-tighten the lug nuts.
2. Lower the vehicle until the suspension is fully loaded with vehicle weight on the wheels.
3. Final-torque the upper control arm chassis bolts to 165 Nm (122 lb-ft) with the suspension loaded — this is critical for correct bushing preload and long-term bushing life.
4. Torque the wheel lug nuts to 136 Nm (100 lb-ft) in a star pattern.
5. Reconnect the 12V low-voltage battery.
6. Exit Jack Mode via the touchscreen if it was enabled.
7. Drive the vehicle a short distance to a flat surface and verify no abnormal noises, pulling, or warning lights.
8. Schedule a four-wheel alignment immediately — do not defer this on a Model Y Performance, as toe/camber error will rapidly destroy the staggered Performance tires.

Verification

• Confirm the new cotter pin is installed on the ball joint nut and legs are bent to secure.
• Verify control arm chassis bolts were torqued at ride height (165 Nm) — incorrect at-droop torque will pre-stress the bushings.
• Check for any suspension or stability-control faults on the Tesla touchscreen (Service > Vehicle Status).
• Test drive at low speed: listen for clunks over bumps, verify steering returns to center, and confirm no pull.
• Inspect the new ball joint boot for proper seating after the test drive.
• Have a four-wheel alignment performed and retain the printout. Re-check toe within 500 miles given the Model Y Performance's high tire wear rate.
• Reminder: rotate tires every 6,250 miles on this vehicle to manage the elevated wear caused by curb weight and instant torque.

More procedures for this vehicle