Replace the front wheel bearing hub assembly on a 2024 Tesla Roadster (Tri Motor AWD). Note: this generation Roadster is a low-production, low-documentation vehicle; verify all fasteners and procedures against current Tesla service documentation before proceeding.

Warnings

Tools required

Parts

• Front wheel bearing hub assembly × 1 — OEM-equivalent front hub assembly for 2024 Roadster — verify with Tesla Parts
• Axle nut (single use if specified) × 1 — OEM axle nut
• New cotter pin or stake nut hardware × 1 — OEM-spec cotter pin
• Hub mounting bolts (if single-use) × 4 — OEM-spec hub bolts

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 Tesla service documentation for the 2024 Roadster (location varies — consult OEM documentation).
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 on the ground.
7. Raise the front of the vehicle and support securely on jack stands at the manufacturer-specified lift points.
8. Remove the front wheel.
9. Inspect the new hub assembly against the old one before installation to confirm correct fitment.

Procedure

1. 1

   Remove axle nut retainer
   If equipped with a cotter pin and castle/retainer cap, remove and discard the cotter pin. If a staked nut is used, relieve the stake before loosening. The axle nut is under very high torque — use a long breaker bar with the vehicle securely supported.
2. 2

   Loosen axle nut
   With an assistant lightly applying the brake (or with the rotor held), loosen the axle nut. Do not fully remove yet if the hub still supports the vehicle weight indirectly via the CV shaft.
3. 3

   Remove brake caliper and bracket
   Remove the front brake caliper assembly and caliper bracket bolts. Suspend the caliper from the suspension with a hook or strap — do not let it hang by the brake hose. Remove the brake rotor; if seized, use the threaded jacking holes if present.
   ⚠Do not depress the brake pedal while the caliper is removed.
4. 4

   Disconnect ABS sensor
   Disconnect the ABS wheel speed sensor connector and free the harness from any clips on the knuckle. If the sensor is bolted to the knuckle/hub, remove the retaining bolt carefully to avoid breaking the sensor.
   Torque spec

   ABS Sensor Bolt10 Nm (7 lb-ft)
5. 5

   Separate CV axle from hub
   Remove the axle nut fully. Push the CV axle stub inward through the hub splines. If seized, use a hub puller — do not strike the axle threads. Support the CV axle to prevent damage to the inner CV joint and boots.
   ⚠Do not over-extend the inner CV joint — damage to the tripod or boot can occur.
6. 6

   Remove hub assembly from knuckle
   Remove the hub-to-knuckle mounting bolts (typically accessed from the rear of the knuckle). Withdraw the hub assembly. If corroded in place, use a soft-faced mallet or a press tool — do not pry on aluminum components.
   Torque spec

   Wheel Bearing Hub Bolts110 Nm (81 lb-ft)
7. 7

   Clean knuckle mating surface
   Thoroughly clean the hub mounting face and bore on the knuckle. Remove any corrosion, debris, or old threadlocker. A clean, flat mating surface is essential for proper bearing preload and runout.
8. 8

   Install new wheel bearing hub assembly
   Position the new hub assembly onto the knuckle. Install the hub mounting bolts with threadlocker if specified by the manufacturer. Torque in a cross pattern.
   Torque spec

   Wheel Bearing Hub Bolts110 Nm (81 lb-ft)
9. 9

   Reinstall ABS sensor
   Clean the ABS sensor tip and bore. Reinstall the sensor and torque the retaining bolt. Reconnect the harness and secure all clips.
   Torque spec

   ABS Sensor Bolt10 Nm (7 lb-ft)
10. 10

    Reinstall CV axle and new axle nut
    Slide the CV axle stub through the new hub. Install a new axle nut. Final torque must be applied with the wheel on the ground or with the brake firmly held — never allow the bearing to spin under torque load. Install a new cotter pin or stake the nut as required.
    ⚠️An improperly torqued axle nut can cause bearing failure or wheel separation. This is a CRITICAL fastener.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
11. 11

    Reinstall rotor, caliper bracket, and caliper
    Install the brake rotor. Reinstall the caliper bracket with threadlocker on the bolts and torque to spec. Reinstall the caliper, ensuring brake hose routing is correct and unstressed.

Reassembly

1. Reinstall the front wheel and snug the lug nuts.
2. Lower the vehicle to the ground.
3. Final-torque the lug nuts in a star pattern.
4. Reconnect the 12V low-voltage battery.
5. Pump the brake pedal until firm before moving the vehicle.
6. Confirm the axle nut is properly secured with new cotter pin or stake.

Verification

• With the vehicle on the ground, confirm no play at the wheel (12-and-6 / 9-and-3 rock test).
• Spin the wheel by hand (vehicle raised) and listen for grinding or roughness — a new bearing should be silent and smooth.
• Take the vehicle on a low-speed test drive; confirm the ABS warning light does not illuminate on the instrument cluster/touchscreen.
• Test at progressively higher speeds, listening for hub noise that changes with cornering load (indicates incorrect preload or contamination).
• Recheck wheel lug nut torque after approximately 50–100 miles.
• While the vehicle is up, this is also a good time to inspect brake fluid condition — Tesla recommends brake fluid replacement every 2 years.

More procedures for this vehicle