Replacement of a front lower control arm on the 2024 Tesla Roadster. Note: this generation Roadster is a low-volume vehicle with limited public service documentation — proceed only if you have access to the official Tesla Service Manual for this platform.

Warnings

Tools required

Parts

• Lower Control Arm Assembly (manufacturer-specified for Roadster) × 1 — Refer to Tesla Service Manual / parts catalog for this VIN
• Ball Joint Cotter Pin × 1 — New cotter pin — never reuse
• Control Arm Pivot Bolts/Hardware (if specified single-use) × 1 — Replace if OEM specifies single-use; otherwise reuse

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 per the Tesla Service Manual for this Roadster (location varies — refer to manual).
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. Confirm you have the official Tesla Service Manual section for this VIN — Roadster suspension hardware and procedures may differ from any other Tesla.
7. Loosen wheel lug nuts on the affected corner while the vehicle is on the ground.
8. Raise the vehicle using manufacturer-specified lift points and support securely on jack stands. Chock the opposite wheels.
9. Remove the wheel and set aside.
10. Inspect all suspension hardware for corrosion; pre-soak with penetrating oil if needed.

Procedure

1. 1

   Document and photograph the suspension assembly
   Before disassembly, photograph the control arm orientation, bushing alignment marks, sway bar link routing, and any shims or alignment cams. The Roadster's suspension geometry is sensitive; reference photos help reassembly.
2. 2

   Disconnect the sway bar end link
   Locate the sway bar end link attached near the lower control arm. Hold the link's internal shaft with an Allen key while loosening the nut with a wrench to prevent the stud from spinning. Separate the link from the control arm or sway bar as needed for clearance.
   Torque spec

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

   Support the lower control arm
   Place a floor jack with a rubber pad under the lower control arm near the ball joint. Apply just enough pressure to support the arm without lifting the chassis off the stands. This contains spring/strut energy when the ball joint is released.
   ⚠Failure to support the control arm can cause sudden, forceful movement when the ball joint is released.
4. 4

   Separate the ball joint from the steering knuckle
   Remove the cotter pin and discard it. Loosen the ball joint nut but do not fully remove it — leave it threaded a few turns to catch the joint. Use a ball joint separator to break the taper. Once free, remove the nut and lower the knuckle away from the ball joint stud. Support the knuckle/hub assembly so it does not hang on the brake hose or any wiring.
   ⚠Do not let the steering knuckle hang by the brake hose or wheel speed sensor wiring.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
5. 5

   Identify and mark control arm pivot hardware
   Locate the inboard pivot bolts where the control arm attaches to the chassis/subframe. If alignment cams or eccentric washers are present, mark their position with a paint pen so the alignment is approximated on reassembly. Refer to the Tesla Service Manual to confirm whether eccentrics are used on this Roadster.
6. 6

   Remove the control arm pivot bolts
   Slowly lower the supporting jack to relieve any residual preload, then remove the inboard pivot bolts. Retain hardware unless OEM specifies single-use bolts.
   Torque spec

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

   Remove the lower control arm
   Maneuver the control arm out of the chassis pocket. Inspect the bushing pockets and ball joint stud bore for damage, corrosion, or elongation. Compare the new arm to the old one to confirm correct part fitment before installation.
   ℹ️If the new arm does not match the old one exactly, STOP — verify part number against the Tesla Service Manual / parts catalog for this VIN.
8. 8

   Install the new lower control arm — inboard pivots
   Position the new control arm into the chassis pocket and start both pivot bolts by hand. Align eccentric washers to the marks made earlier (if applicable). Snug the bolts but do NOT torque to final spec yet — final torque is applied at ride height.
9. 9

   Reconnect the ball joint to the steering knuckle
   Raise the control arm with the floor jack to align the ball joint stud with the knuckle. Install the ball joint nut and torque to specification. Continue tightening (within manufacturer-allowed range) only as needed to align a castellation slot with the cotter pin hole — never back off. Install a NEW cotter pin and bend it per the service manual.
   ⚠️Always use a NEW cotter pin. A loose ball joint nut can cause loss of steering control.
   Torque spec

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

    Reconnect the sway bar end link
    Reinstall the sway bar end link, holding the internal shaft with an Allen key while torquing the nut to specification.
    Torque spec

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

    Reinstall the wheel
    Mount the wheel and hand-thread all lug nuts. Snug them in a star pattern, then lower the vehicle until the tire just contacts the ground before final torque.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
12. 12

    Final torque pivot bolts at ride height
    Lower the vehicle fully onto its wheels (or onto drive-on ramps / a scissor lift that allows the suspension to be loaded). With the vehicle at normal ride height, torque the control arm inboard pivot bolts to specification. This prevents the bushings from being preloaded in a static, off-load position.
    ⚠Skipping ride-height torquing will twist the bushings and cause early failure.
    Torque spec

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

    Final torque wheel lug nuts
    With the vehicle on the ground, torque the lug nuts to specification in a star/cross pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Confirm all hardware is torqued to the verified specifications listed.
2. Confirm a NEW cotter pin is installed in the ball joint nut and properly bent.
3. Reconnect the 12V low-voltage battery per the Tesla Service Manual.
4. Power the vehicle on and verify no chassis or stability-control faults are displayed.
5. Schedule and perform a four-wheel alignment before returning the vehicle to service.

Verification

• Visually inspect that the ball joint cotter pin is installed and bent correctly.
• Confirm sway bar link is seated and torqued; no thread showing beyond specification.
• With wheels on the ground, push down on the front fender and verify smooth, damped rebound (no clunking from a loose ball joint or pivot bolt).
• Test drive at low speed in a safe area, listening for clunks over bumps and confirming the steering tracks straight.
• Have a four-wheel alignment performed — control arm replacement always disturbs camber/caster/toe.
• Re-check pivot bolt torque after the first 100 miles, as is good practice on critical suspension fasteners.
• Note: While performing front suspension service, this is a good time to inspect brake fluid age (Tesla recommends replacement every 2 years) and verify front drive unit gear oil service interval (Tesla now recommends periodic service, not 'lifetime').

More procedures for this vehicle