Replace the inner tie rod end on a 2024 Tesla Roadster (Tri Motor). Note: this generation Roadster does not share the original Lotus-based platform — service information is extremely limited and not publicly released by Tesla. Confidence in model-specific details is low; defer to Tesla Service documentation when available.

Warnings

Tools required

Parts

• Inner tie rod end (manufacturer-specified for 2024 Roadster) × 1 — OEM Tesla Roadster inner tie rod — refer to Tesla Service Manual
• Steering rack bellows / boot (recommended replacement when inner tie rod is disturbed) × 1 — OEM specification
• Bellows boot clamps (inner and outer) × 2 — OEM specification
• Cotter pin for tie rod castle nut × 1 — OEM specification

Preparation

1. Park on level ground, place in P, 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 (or low-voltage) battery per Tesla service documentation for this vehicle. Location on the 2024 Roadster is not publicly verified — refer to the Tesla Service 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. Loosen front lug nuts while the vehicle is on the ground.
7. Raise the front of the vehicle and support on jack stands at manufacturer-specified lift points. Remove the front wheel on the affected side.
8. If equipped, remove the front underbody/aero panel to access the steering rack and inner tie rod. Use the manufacturer-specified fastener pattern.
9. Center and lock the steering wheel (steering wheel lock or seatbelt-through-wheel method) to prevent the clockspring from rotating while the tie rod is disconnected.

Procedure

1. 1

   Document existing alignment reference
   With the wheel removed, measure and record the exposed thread length between the outer tie rod end and the inner tie rod shaft, or count the number of visible threads. This allows reassembly close to the original toe setting so the vehicle can be driven (carefully, short distance) to alignment.
2. 2

   Separate outer tie rod end from steering knuckle
   Remove the cotter pin from the outer tie rod castle nut, then loosen and remove the nut. Separate the outer tie rod stud from the steering knuckle using a proper tie rod separator tool. Avoid prying directly against any aluminum knuckle face.
   ⚠Discard the cotter pin — a new one is required on reassembly.
3. 3

   Loosen tie rod jam (lock) nut
   Loosen the jam nut between the outer tie rod end and the inner tie rod shaft. Do not unthread the outer tie rod from the inner shaft yet — leave it in place to preserve your reference measurement, OR thread the outer off counting exact turns.
4. 4

   Remove outer tie rod from inner shaft
   Unthread the outer tie rod end from the inner tie rod shaft, counting and recording the number of rotations. Set the outer tie rod aside for reuse if it is in good condition.
5. 5

   Remove steering rack bellows (boot)
   Cut or release the inner and outer bellows clamps and slide the rubber bellows off the inner tie rod and rack housing. Inspect the boot for tears; replace as a matter of course since it has been disturbed.
   ℹ️Inspect the rack shaft for grease loss, contamination, scoring, or moisture intrusion. Any of these warrants stopping and evaluating the rack itself.
6. 6

   Unlock and remove inner tie rod from steering rack
   If a staking tab or locking washer is present, release it per the manufacturer-specified method. Using an inner tie rod tool that engages the flats of the inner tie rod housing, unthread the inner tie rod from the steering rack shaft. Hold the rack shaft from rotating by its flats only — never grip the rack shaft with pliers or a pipe wrench.
   ⚠️Do NOT clamp or rotate the rack shaft with anything that could mar it. A scored rack shaft will destroy the new bellows seal and lead to rack failure.
7. 7

   Inspect rack shaft and threads
   Clean the threaded end of the rack shaft and inspect for damage. Verify there is no grit or metallic debris. Apply fresh manufacturer-specified rack grease if recommended by the inner tie rod kit.
8. 8

   Install new inner tie rod
   Thread the new inner tie rod onto the rack shaft by hand to verify clean engagement. Torque the inner tie rod to the OEM specification using the inner tie rod tool. The Tesla-published torque for this specific fastener on the 2024 Roadster is not in our verified list — torque to OEM specification — refer to Tesla Service Manual. If a staking tab is provided, stake it per the manufacturer's procedure.
   ⚠Do NOT substitute the outer tie rod or jam nut torque values for the inner tie rod-to-rack joint. They are different fasteners.
9. 9

   Install new bellows boot
   Slide the new bellows over the inner tie rod and seat it onto the rack housing and onto the inner tie rod shoulder. Install new clamps at both ends. Ensure the boot is not twisted, which would cause it to tear during steering travel.
10. 10

    Reinstall outer tie rod end
    Thread the jam nut onto the inner tie rod shaft, then thread the outer tie rod end on, returning it to the recorded thread count / exposed thread length from Step 1. Do not final-torque the jam nut yet — alignment will set final toe.
11. 11

    Reconnect outer tie rod to steering knuckle
    Insert the outer tie rod stud into the knuckle. Install the castle nut and torque to specification, then advance (never back off) the nut as needed to align the cotter pin hole. Install a NEW cotter pin and bend the legs per standard practice.
    ⚠Always tighten further to align the cotter pin hole — never loosen. Loosening reduces clamp load on a critical steering joint.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
12. 12

    Snug jam nut for transport to alignment
    Snug the tie rod jam (lock) nut hand-tight plus a partial turn for the drive to alignment. Final torque is applied AFTER alignment is set.

Reassembly

1. Reinstall the front wheel and run lug nuts down by hand.
2. Lower the vehicle to the ground.
3. Final-torque the lug nuts in a star pattern.
4. Reinstall any aero/underbody panels removed for access.
5. Reconnect the low-voltage battery per Tesla service documentation.
6. Drive the vehicle slowly and directly to an alignment rack — do not drive at speed or any extended distance until alignment is verified.
7. Have a 4-wheel alignment performed. After toe is set, hold the inner tie rod shaft and torque the tie rod jam (lock) nut to specification.
8. Re-verify the bellows boot is not twisted and clamps are secure after the wheels have been steered lock-to-lock on the alignment rack.

Verification

• With the vehicle on the ground, steer lock-to-lock by hand (engine/HV off). Motion should be smooth with no clunks, binding, or grinding from the rack.
• Visually inspect the new bellows at full left and full right lock — it must not be twisted, stretched, or pinched.
• Confirm a new cotter pin is installed at the outer tie rod castle nut and legs are properly bent.
• Confirm the alignment shop's printout shows toe within Tesla specification (specification is not in our verified data — refer to Tesla Service Manual for the 2024 Roadster).
• On a short, low-speed test drive, verify the steering wheel is centered and the vehicle tracks straight with no pull, no vibration, and no warning messages on the touchscreen.
• Recheck the tie rod jam nut torque (Tie Rod Lock Nut, 68 Nm / 50 lb-ft) after alignment is finalized.
• Note: this job does not coincide with a scheduled Tesla service interval, but if the vehicle is approaching brake fluid (2-year), cabin filter (2-year), or tire rotation (every 6,250 mi) intervals, consider addressing them while the vehicle is already in the air.

More procedures for this vehicle