Replace both outer tie rod ends on the 2024 Tesla Roadster (Tri Motor). Note: this vehicle's chassis architecture is largely unique and service documentation is scarce — confirm fastener specifications against the official Tesla Service Manual before final assembly, and always finish with a four-wheel alignment.

Warnings

Tools required

Parts

• Outer tie rod end assembly (manufacturer-specified) × 2 — OEM tie rod end for 2024 Tesla Roadster — verify with Tesla Parts
• Castle nut / tie rod end nut (if not supplied with tie rod) × 2 — OEM specification
• Cotter pin × 2 — OEM specification — never 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 (or 16V/48V on applicable models) low-voltage battery. Refer to the Tesla Service Manual for exact battery location on the 2024 Roadster, as this platform differs significantly from other Tesla models.
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 wheel lug nuts while the vehicle is still on the ground.
7. Raise the front of the vehicle using manufacturer-specified lift points and support securely on jack stands or a lift.
8. Remove both front wheels and set aside.
9. Center the steering wheel and lock it in position (steering wheel lock or seat-belt method) so the rack does not rotate during the repair.

Procedure

1. 1

   Inspect and document current tie rod geometry
   Before loosening anything, clean the threads of each inner tie rod and lock nut with a wire brush and penetrating oil. Using a paint pen or marker, mark the position of the lock nut on the inner tie rod threads. Measure and record the exposed thread length (or overall tie rod length from inner pivot to ball stud center) on BOTH sides. This is your reference for rough toe re-set so the vehicle is drivable to the alignment shop.
2. 2

   Remove cotter pin and castle nut from outer tie rod end
   Straighten and extract the cotter pin from the outer tie rod ball stud. Discard it — never reuse a cotter pin. Loosen and remove the castle nut from the ball stud. If the ball stud spins, apply downward pressure on the tie rod end or use a wrench on the flat (if equipped) to hold it.
3. 3

   Separate outer tie rod end from steering knuckle
   Use a proper tie rod end puller (separator tool) to press the ball stud out of the steering knuckle. Avoid pickle forks if possible — they damage the boot and can deform aluminum knuckles. Once free, swing the tie rod end clear of the knuckle.
   ⚠Do not strike the knuckle with a steel hammer. The Roadster's chassis and suspension components include aluminum and composite materials that crack rather than deform.
4. 4

   Loosen the inner tie rod lock nut
   While holding the inner tie rod stationary with a wrench on its flats, break loose the lock nut that secures the outer tie rod end to the inner tie rod threads. Do NOT yet unthread the outer tie rod end.
5. 5

   Count turns while removing the outer tie rod end
   Unthread the outer tie rod end from the inner tie rod, counting full and partial turns precisely. Record this number for each side. Threading the new tie rod end on by the same count will preserve toe close enough for safe transport to alignment.
6. 6

   Repeat removal on opposite side
   Perform steps 2–5 on the opposite side of the vehicle. Keep left and right hardware separated and labeled.
7. 7

   Compare new and old tie rod ends
   Place the new tie rod end alongside the old one. Verify thread direction (some vehicles use one LH and one RH thread side), thread pitch, ball stud taper angle, ball stud diameter, and overall length match. If anything is different, STOP and verify the correct part number with Tesla before proceeding.
   ⚠️Installing a tie rod end with the wrong taper or thread will fail catastrophically. Verify part match before installation.
8. 8

   Install new outer tie rod end onto inner tie rod
   Slide the lock nut onto the inner tie rod first. Thread the new outer tie rod end onto the inner tie rod by the SAME number of turns recorded in step 5. Snug the lock nut by hand for now — final torque is set after alignment.
9. 9

   Insert ball stud into steering knuckle
   Position the new tie rod end's ball stud into the steering knuckle taper. Ensure the boot is seated correctly and not pinched. Install a new castle nut and tighten to specification.
   Torque spec

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

    Install new cotter pin
    If the castle nut slots do not align with the cotter pin hole, tighten the nut SLIGHTLY further (never loosen) until alignment is achieved. Insert a new cotter pin and bend the legs over per OEM practice. Trim excess if needed.
    ⚠Never back off a castle nut to align the cotter pin hole — always tighten further within reason. If the next slot is not reachable within a few degrees, re-evaluate fastener and component condition.
11. 11

    Repeat installation on opposite side
    Perform steps 8–10 on the opposite side of the vehicle.
    Torque spec

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

    Snug lock nuts for transport
    With both tie rod ends installed and ball studs secured, snug the inner tie rod lock nuts to a moderate setting so the vehicle can be safely driven to the alignment rack. Do NOT apply final torque yet — final torque happens after alignment adjustment is complete.

Reassembly

1. Reinstall the front wheels. Hand-thread all lug nuts before applying torque.
2. Lower the vehicle to the ground.
3. Torque front wheel lug nuts in a star pattern to specification.
4. Reconnect the 12V/LV battery.
5. Cycle the steering lock-to-lock with the vehicle running (in a safe area or on the alignment rack) and verify no binding or unusual noise.
6. Drive carefully and directly to an alignment shop — avoid highway speeds and aggressive maneuvers until alignment is complete.
7. After four-wheel alignment is performed and toe is set, torque the inner tie rod lock nuts to specification as the final step.

Verification

• Confirm both new cotter pins are installed and properly bent — visual inspection from below.
• Confirm tie rod boots are intact, seated, and not twisted at full lock left and full lock right.
• Confirm no play in the new tie rod ends by grasping the tire at 3 and 9 o'clock and rocking — there should be zero detectable lash from the tie rod end.
• Have a four-wheel alignment performed by a shop with current Tesla Roadster specs. Confirm toe, camber, and caster are within OEM range.
• After alignment, verify inner tie rod lock nuts are torqued to the specified value and that the steering wheel is centered when driving straight.
• Test drive at low speed, then progressively higher speeds, listening for clunks and watching for steering pull or wander.
• Re-check fasteners after the first 100 miles of driving.

More procedures for this vehicle