Replace a front sway bar end link on a 2012 Tesla Roadster. The Roadster shares its front suspension architecture with the Lotus Elise/Exige, so most chassis hardware is Lotus-pattern rather than Tesla-specific.

Warnings

Tools required

Parts

• Front sway bar end link assembly (Lotus Elise/Roadster pattern) × 1 — Manufacturer-specified front anti-roll bar drop link — verify against Roadster parts catalog
• Replacement self-locking nuts (if originals are nylocs and reused condition is poor) × 2 — OEM-spec self-locking nut

Preparation

1. Park on level ground, place in P (or in gear if equipped with the manual transmission variant), 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 before working under the car. On the Roadster the 12V auxiliary battery is located in the front service compartment — refer to the Roadster Owner's Manual for exact access.
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. Chock the rear wheels.
7. Loosen the front lug nuts while the wheel is still on the ground.
8. Raise the front of the vehicle at the manufacturer-specified jacking points and support on jack stands. Never rely on the jack alone.
9. Remove the front wheel on the side being serviced.

Procedure

1. 1

   Inspect and identify the sway bar link
   Locate the front anti-roll bar end link connecting the sway bar to the lower control arm/strut bracket (Lotus-style layout). Identify the upper and lower fasteners and confirm whether the link uses a stud-with-nut design (most common) or a through-bolt. Spray penetrating oil on both fasteners and allow it to soak.
2. 2

   Hold the link shaft and loosen the nuts
   Insert an Allen/hex key into the end of the link stud to prevent the ball stud from spinning, then loosen and remove the upper and lower link nuts with a wrench. If the stud spins freely due to a worn internal socket, grip the link body carefully with locking pliers as a last resort.
   ⚠Do not use an impact gun on a spinning ball-stud link — it will destroy the boot and can damage the sway bar mount.
   Torque spec

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

   Remove the old end link
   Once both nuts are off, separate the link from the sway bar and from the lower mount/strut bracket. Note the orientation (which end was up) and any spacers or washers — they must be reinstalled in the same order.
4. 4

   Compare old and new parts
   Place the new link next to the old one and verify identical length, thread size, stud taper, and boot orientation. Roadster front links are Lotus-pattern; verify any aftermarket replacement matches exactly before installation.
   ⚠An incorrect-length link will preload the sway bar and can cause uneven handling or premature bushing failure.
5. 5

   Install the new link
   Install the new link in the same orientation as the original, with any spacers/washers in their original positions. Thread both nuts on by hand to seat the studs.
6. 6

   Torque the link nuts
   Hold the link stud with an Allen key and torque both upper and lower nuts to specification using a calibrated torque wrench.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
7. 7

   Inspect adjacent hardware
   While access is available, inspect the sway bar bushings, bracket bolts, and lower control arm bushings for cracking or play. If the sway bar bracket bolts were disturbed, torque them to the verified specification.
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)

Reassembly

1. Reinstall the front wheel and hand-tighten the lug nuts.
2. Lower the vehicle so the wheel just touches the ground, then torque the lug nuts in a star pattern to specification.
3. Lower the vehicle fully to the ground.
4. Reconnect the 12V low-voltage battery.
5. Allow the vehicle to sit at normal ride height for a moment before the first drive so the suspension settles.

Verification

• With the vehicle on the ground, push down on each front corner — the suspension should rebound smoothly with no clunking from the link area.
• Perform a slow-speed left/right steering test in a parking lot and listen for clunks or rattles over small bumps; a properly torqued link should be silent.
• Road test at moderate speed and verify steering feel is symmetric left-to-right with no new vibration or pull.
• Re-check the link nut torque after the first 100–200 miles, as Lotus-pattern ball-stud links are known to settle slightly after installation.
• Note: The Roadster predates Tesla's 'no scheduled maintenance' marketing — it has a real Tesla-published service schedule. While under the car, verify brake fluid is within its 2-year replacement interval and that the transmission/gearbox oil and rear differential fluid have been serviced per the Roadster Owner's Manual.

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