Replace upper and lower ball joints on a 2012 Tesla Roadster. Note: the Roadster shares its chassis with the Lotus Elise/Exige, so suspension components and procedures largely follow Lotus service practice rather than later Tesla models.

Warnings

Tools required

Parts

• Upper ball joint (manufacturer-specified for Roadster/Lotus chassis) × 2 — OEM Lotus/Tesla Roadster upper ball joint
• Lower ball joint (manufacturer-specified for Roadster/Lotus chassis) × 2 — OEM Lotus/Tesla Roadster lower ball joint
• New cotter pins for ball joint castle nuts × 4 — Standard size matching OEM nut
• New pinch bolt(s) if equipped × 2 — OEM single-use pinch bolt

Preparation

1. Park on level ground, place transmission in gear (1st or Reverse) on manual cars or P on automated units, engage 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 auxiliary battery (located in the front trunk/frunk area on the Roadster) before lifting the vehicle. Refer to architecture notes for exact location.
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 wheel lug nuts while the vehicle is still on the ground.
7. Raise the vehicle using the manufacturer-specified jacking points (the Roadster has dedicated chassis lift pads — DO NOT lift on the aluminum tub directly) and support securely on jack stands.
8. Remove the wheel(s) on the side(s) being serviced.
9. Take reference photos of suspension geometry, shim placement, and any alignment marks before disassembly.

Procedure

1. 1

   Inspect and document existing suspension
   Visually inspect the upper and lower control arms, ball joint boots, and surrounding hardware. Note any shims, eccentric washers, or alignment marks. Photograph orientation of each ball joint and the routing of the brake line and ABS sensor wire.
2. 2

   Disconnect sway bar link
   Remove the sway bar end link from the lower control arm to free the suspension. Hold the link's internal shaft with an Allen key while loosening the nut to prevent spinning.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
3. 3

   Support the lower control arm
   Place a floor jack under the lower control arm with light upward pressure to control spring/strut load when the ball joints are released. The Roadster uses a coilover-style strut — the lower arm carries the spring reaction.
   ⚠Do not allow the hub assembly to swing freely once both ball joints are disconnected — the brake hose and ABS wire will be damaged.
4. 4

   Remove brake caliper and rotor (if required for access)
   If the upright must be moved significantly to release the ball joints, unbolt the brake caliper and suspend it from the chassis with mechanic's wire — DO NOT let it hang by the brake hose. Remove the rotor if needed for clearance. Torque to OEM specification on reassembly — refer to Tesla Service Manual.
5. 5

   Release the upper ball joint
   Straighten and remove the cotter pin from the upper ball joint castle nut. Loosen the nut but leave it threaded a few turns to capture the joint. Use a proper ball joint separator (preferred) to break the taper. Avoid pickle-fork use if the boot is to be reused — but since you are replacing the joint, the fork is acceptable. Once the taper releases, remove the nut fully and separate the joint from the upright.
   ⚠Do not strike the aluminum upright with a steel hammer to free the taper. Use a separator tool.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
6. 6

   Release the lower ball joint
   Repeat the cotter-pin and castle-nut removal on the lower ball joint. Maintain jack support of the lower control arm. Use a separator to break the taper, then remove the nut and lower the arm slightly to free the upright.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
7. 7

   Remove ball joints from control arm or upright
   Roadster ball joints may be press-fit into the control arm, threaded, or bolt-in depending on revision. Identify your configuration before forcing anything. For press-fit, use a manufacturer-specified ball joint press. For bolt-in joints, remove the retaining hardware. Torque to OEM specification — refer to Tesla Service Manual on reinstall.
   ⚠If the joint configuration does not match what you see, STOP and verify against a Lotus Elise/Exige service reference — the Roadster suspension is closely related.
8. 8

   Install new ball joints
   Install the new upper and lower ball joints into the control arm or upright per your configuration. Ensure boots are oriented correctly and not pinched. Apply manufacturer-specified grease if the joint is greasable.
9. 9

   Reconnect upright to control arms
   Insert the upper and lower ball joint studs into the upright. Install the castle nuts and tighten to spec. Advance the nut (do not back off) to align the cotter pin hole, then install a NEW cotter pin and bend the legs over fully.
   ⚠️Never back off a castle nut to align the cotter pin slot — only tighten further. A loose ball joint nut can cause loss of vehicle control.
   Torque spec

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

    Reconnect sway bar link
    Reinstall the sway bar end link to the lower control arm. Hold the internal shaft with an Allen key while torquing the nut.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
11. 11

    Reinstall brake hardware (if removed)
    Reinstall the rotor and brake caliper if they were removed. Verify brake hose and ABS wire routing is correct and unstressed at full steering lock and full suspension travel.
12. 12

    Reinstall wheel and lower vehicle
    Mount the wheel and snug the lug nuts. Lower the vehicle until the tire just contacts the ground, then final-torque control arm pivot bolts (if disturbed) with weight on the suspension to set bushing preload at ride height.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Lower the vehicle fully to the ground.
2. Final-torque wheel lug nuts in a star pattern.
3. Reconnect the 12V auxiliary battery.
4. Cycle the steering lock-to-lock with the vehicle stationary on the ground to settle suspension geometry.
5. Verify no warning lights related to ABS or stability systems on the instrument cluster after a short drive.

Verification

• Confirm new cotter pins are installed at both upper and lower ball joints and bent over fully.
• Bounce-test the corner: suspension should compress and rebound without clunking.
• Drive at low speed and check for steering pull, clunks over bumps, or loose feel — investigate immediately if present.
• Schedule a four-wheel alignment within the first few miles. Roadster camber and toe are sensitive and tire wear will be rapid if neglected.
• Re-inspect torque on ball joint nuts and control arm bolts after the first 100-200 miles of driving — any settling can be caught before it becomes a safety issue.
• Note: this is a chassis service, not an electrical system service, so no Tesla published service interval directly applies. However, since the vehicle is on a lift, take the opportunity to inspect brake fluid (Tesla recommends replacement every 2 years regardless of mileage) and gearbox oil condition (Roadster manual gearbox uses 75W-90 GL-5).

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