Replace the outer tie rod end on a 2024 Tesla Roadster (Tri Motor AWD). Note: production Roadster service data is extremely limited; this procedure follows generic outer tie rod best practices and must be cross-referenced against the official Tesla Service Manual before performing the work. A four-wheel alignment is mandatory after this job.

Warnings

Tools required

Parts

• Outer tie rod end assembly (manufacturer-specified for Tesla Roadster) × 1 — OEM Tesla Roadster outer tie rod end — verify with Tesla parts
• New cotter pin for castle nut × 1 — Size to match castle nut

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 low-voltage (12V/16V) auxiliary battery per the Tesla Service Manual for this Roadster. Refer to the manual for exact location and 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. Confirm the replacement tie rod end matches the side (left/right) and the existing part exactly.
7. Loosen front wheel lug nuts slightly while the vehicle is still on the ground.
8. Raise the front of the vehicle at the manufacturer-specified jack points and support securely on jack stands. Never work under a vehicle supported only by a jack.
9. Remove the front wheel on the affected side.

Procedure

1. 1

   Inspect and clean the tie rod assembly
   Wire-brush dirt and debris from the tie rod end, the inner tie rod lock nut, and the steering knuckle taper. Apply penetrating oil to the lock nut threads and the castle nut. Allow to soak.
2. 2

   Mark the existing tie rod position
   Using a paint marker, mark the inner tie rod shaft where the lock nut currently sits. Measure and record the exposed thread length between the lock nut and the outer tie rod end. This reference is used to set the replacement near factory toe so the vehicle is drivable to alignment.
   ℹ️This is a reference only — a professional alignment is still required afterward.
3. 3

   Loosen the inner lock nut
   Hold the inner tie rod shaft with an open-end wrench and break loose the tie rod lock nut. Back it off just enough to free rotation against the outer tie rod end — do not run it down the shaft.
4. 4

   Remove the cotter pin and castle nut
   Straighten and remove the cotter pin from the outer tie rod end stud. Discard the cotter pin — it must not be reused. Loosen the castle nut but leave it threaded on the last few threads to protect the stud during separation.
5. 5

   Separate the tie rod end from the steering knuckle
   Use a proper tie rod end puller to break the tapered stud free from the steering knuckle. Avoid pickle forks unless the boot is being discarded, as they can damage the knuckle, the boot, and any surrounding aluminum components. Once the taper releases, remove the castle nut fully and lift the stud out of the knuckle.
   ⚠Do not strike the aluminum steering knuckle with a hammer. Damage may not be visible but can compromise the part.
6. 6

   Count turns while removing the outer tie rod end
   While holding the inner tie rod shaft stationary, unscrew the outer tie rod end from the inner tie rod. Count the exact number of turns required for full removal and record it. This is the most accurate way to install the replacement at the same toe setting.
7. 7

   Install the new outer tie rod end
   Thread the new outer tie rod end onto the inner tie rod shaft using the same number of turns recorded in the previous step. Verify the exposed thread length matches your earlier measurement. Do not snug the lock nut yet.
8. 8

   Seat the stud in the steering knuckle
   Insert the tapered stud of the new tie rod end into the steering knuckle. Ensure the boot is seated correctly and not pinched. Hand-thread the castle nut onto the stud.
9. 9

   Torque the castle nut and install new cotter pin
   Torque the castle nut to specification. If the slots in the castle nut do not align with the cotter pin hole, tighten further (never loosen) until alignment is achieved, staying within an acceptable additional rotation. Install a NEW cotter pin and bend the legs over to secure.
   ⚠️Never back off the castle nut to align the cotter pin slot. Always tighten.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
10. 10

    Preliminary lock nut snug
    Snug the inner tie rod lock nut against the new outer tie rod end by hand and with a wrench just enough to prevent rotation while moving the vehicle. Final torque is applied AFTER alignment.
    ℹ️Do not apply final lock nut torque until the alignment shop has set toe.

Reassembly

1. Reinstall the front wheel and hand-tighten the lug nuts.
2. Lower the vehicle to the ground.
3. Torque the wheel lug nuts in a star pattern to specification.
4. Reconnect the low-voltage auxiliary battery per the Tesla Service Manual sequence.
5. Drive the vehicle ONLY the minimum distance required to reach an alignment rack. Pay attention to any pull, vibration, or unusual steering feel — return immediately if anything feels wrong.
6. After alignment is completed and toe is set, torque the Tie Rod Lock Nut to its final specification while holding the inner tie rod stationary.

Verification

• Confirm the new cotter pin is fully installed and bent over on the castle nut.
• Visually verify the boot on the new tie rod end is seated, undamaged, and has no twist.
• Confirm the lock nut is fully torqued AFTER alignment — refer to torque spec for Tie Rod Lock Nut.
• Confirm wheel lug nuts torqued to spec; re-torque after approximately 50 miles.
• Have a four-wheel alignment performed and verify toe, camber, and caster are within Tesla Roadster specification.
• Test drive at low speed first: check for steering centering, any pulling, clunks over bumps, or steering free play. Escalate any abnormality before higher-speed driving.
• Service-interval reminder unrelated to this job but worth checking while the vehicle is up: tire rotation is recommended every ~6,250 miles on Tesla vehicles, and brake fluid every 2 years.

More procedures for this vehicle