2021-2025 Tesla Model S Control Arms: Diagnosing Knocks, Creaks, and Steering Wander
This guide covers the common failure symptoms, known issues, and replacement costs for the suspension control arms on the 2021-2025 Tesla Model S.
- The most common failure symptom is a creaking or clunking noise from the front suspension, especially over bumps or during low-speed turns.
- While no specific recalls exist for 2021-2025 Model S control arms, premature wear is a known issue, and Tesla may cover labor costs for replacement as a goodwill gesture.
- Complete failure can affect steering control, so it is unsafe to ignore symptoms like steering wander or loud knocking noises.
- Replacement is a complex job (Difficulty 4/5) that requires significant disassembly and a mandatory four-wheel alignment, making it unsuitable for most DIY mechanics.
Known Issues for 2021-2025 Tesla Model S
While many widely publicized suspension recalls and technical service bulletins (TSBs) apply to pre-2021 Model S vehicles, the 2021-2025 "Refresh" and Plaid models are not immune to control arm issues. Owners of these newer models report similar symptoms, primarily related to premature wear of the ball joints and bushings. The most common complaint is noise, which can manifest in several ways:
- Creaking or Squeaking: A persistent creaking sound, often described as sounding like an old door, is common when steering at low speeds or driving over bumps. This is frequently caused by moisture getting into the upper control arm's ball joint, washing out the factory grease.
- Knocking or Crunching: Some 2023 Plaid owners have reported a distinct knocking, crunching, or grinding sound when the steering is at or near full lock. This noise can be more pronounced on wet roads and may indicate excessive play in a worn ball joint or bushing.
- General Clunking: A clunking or popping noise when driving over bumps, potholes, or uneven pavement is a classic sign of a failing control arm component.
The underlying cause is often attributed to the vehicle's heavy weight and high torque output, which places significant strain on all suspension components. There are no active recalls specifically for control arms on the 2021-2025 Model S as of mid-2026.
Symptoms of a Failing Suspension Control Arm
A bad control arm is really a failure of its bushings or ball joint. Here are the most common symptoms to watch and listen for.
1. Clunking, Creaking, or Knocking Noises
This is the most frequent symptom. Worn bushings or a dry ball joint will cause noise as the suspension moves. You'll hear it most when going over bumps, making sharp turns, or during braking. On the Model S, a persistent creak at low speeds often points directly to the upper control arm ball joints.
2. Steering Wander or Pulling
If the bushings or ball joints have excessive play, they can no longer hold the wheel in the correct alignment. This can cause the vehicle to feel unstable, wander in its lane, or pull to one side, requiring constant steering correction from the driver.
3. Steering Wheel Vibration
Excessive vibration felt through the steering wheel, especially at higher speeds, can be caused by a worn control arm. The looseness in the assembly allows the wheel to oscillate slightly, which translates into a noticeable vibration in the cabin.
4. Uneven Tire Wear
A failing control arm allows the wheel's alignment (specifically camber and toe) to shift dynamically. This causes tires to wear unevenly. A bad lower control arm often causes wear on the inside edge of the tire, while a bad upper control arm can cause wear on the outside edge.
Warning: A completely failed control arm or separated ball joint can cause a loss of steering control. Do not ignore symptoms of a bad control arm.
Buying a Used 2021-2025 Model S Control Arm
Given the high cost of new OEM parts, a quality used OEM control arm is an excellent value. Because these parts are known to wear, a thorough inspection is critical. Here’s what to check before you buy:
- Inspect the Bushings: The rubber bushings are the most common failure point. Look for any cracks, tears, or signs of dry rot in the rubber. The rubber should be pliable, not hard or brittle. Check if the inner metal sleeve has separated from the surrounding rubber, which indicates a complete failure.
- Check the Ball Joint: The ball joint should be tight. Try to move the ball joint stud by hand; there should be no noticeable play or looseness. Squeeze the rubber dust boot to check for cracks or splits. A torn boot allows dirt and water to enter, causing rapid wear.
- Examine the Arm Itself: Inspect the aluminum arm for any signs of cracks, deep gouges, or bending, especially around the welds and mounting points. Any damage to the arm itself means it is unsafe to use. Pay close attention to any signs of impact from an accident.
- Verify Part Numbers: The 2021+ Model S uses different parts than earlier generations. Ensure the part number matches your vehicle. Key part numbers for the front upper arms are 1420321-00-C (Left) and 1420326-00-C (Right).
Pro Tip: For this specific part, a low-mileage used OEM arm is often a better choice than a cheap, unbranded new aftermarket part. The OEM arms are designed for the specific weight and stresses of the Model S. Many aftermarket options exist, but quality can vary significantly.
Cost Comparison (2021-2025 Tesla Model S)
Repair costs can vary widely based on your location and whether you use Tesla Service or an independent shop.
| Part/Service | Estimated Cost | Notes |
|---|---|---|
| New OEM Part | $400 - $1,100+ (per arm) | Price varies by specific arm (upper, lower, etc.). Tesla does not sell parts directly to consumers, so this cost is part of a service center quote. |
| New Aftermarket Part | $150 - $450 (per arm) | Quality and design can vary. Premium aftermarket arms with improved bearings may cost more. |
| Used OEM Part | $120 - $250 (per arm) | A cost-effective option if the part is inspected carefully for wear. |
| Shop Labor | $400 - $800 | Typically 2-4 hours of labor plus the cost of a mandatory wheel alignment. Tesla labor rates are often $200+/hour, while independent shops may be less. |
| Total Replacement Cost | $1,000 - $2,500+ | Total cost for replacing one or two arms at a service center or independent shop. |
Note: Many owners have reported that Tesla Service Centers may cover the labor cost for control arm replacement as a "goodwill" gesture, even if the vehicle is out of warranty, due to this being a known issue. It is always worth getting a quote directly from Tesla.
Replacement Difficulty: 4/5
Replacing a control arm on a 2021-2025 Model S is a complex job not recommended for beginners. The process involves significant disassembly.
- Access: Replacing the front upper control arms requires removing the front wheels, wheel arch liners, and the large underhood storage unit ("frunk") to access the bolts on top of the shock tower.
- Special Tools: The procedure may require a special ride height tool to properly torque the bushing bolts with the suspension at the correct angle.
- Air Suspension: The vehicle's air suspension must be put into "Jack Mode" before lifting to prevent damage.
- Alignment Required: A full four-wheel alignment is mandatory after replacement to ensure proper handling, safety, and to prevent rapid tire wear.
Due to these complexities, most owners should entrust this job to a qualified technician familiar with Tesla vehicles.
Frequently Asked Questions (FAQ)
Can I just replace the bad bushing or ball joint?
Most control arms for the Tesla Model S are sold as a complete assembly with the bushings and ball joint pre-installed. While some specialized shops or aftermarket companies offer separate components, it is almost always more time- and cost-effective to replace the entire arm.
Should I replace control arms in pairs?
Yes, it is highly recommended. Suspension components wear at similar rates. If the control arm on one side has failed, the other side is likely not far behind. Replacing them in pairs ensures balanced handling and saves you from paying for a separate alignment job in the near future.
Will a bad control arm cause a dashboard warning light?
Generally, no. A worn mechanical component like a control arm will not trigger a check engine light or a specific suspension warning on its own. However, in extreme cases, if the wheel position is so far off that it affects a wheel speed sensor's reading, it could potentially trigger a secondary warning for the ABS or traction control systems.
Can I fix the squeaking noise by greasing the ball joint?
Some owners have had temporary success by using a special needle fitting on a grease gun to inject grease into the ball joint's rubber boot. While this can quiet the noise for a while, it is not a permanent fix. The boot has already been compromised, and the joint is already worn. Replacement is the only long-term solution.
Technical Specifications
OEM Part Numbers: 1420321-00-B 1420321-00-C 1420326-00-B 1420326-00-C 1027351-00-E 1420421-00-D
Control arms are typically made of cast or forged aluminum. The assembly includes integrated, non-serviceable rubber bushings and a sealed ball joint.
We Have This Part in Stock
The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
- Tesla S:
- 🛍️ Shop This Part
- Known Issues for 2021-2025 Tesla Model S
- Symptoms of a Failing Suspension Control Arm
- 1. Clunking, Creaking, or Knocking Noises
- 2. Steering Wander or Pulling
- 3. Steering Wheel Vibration
- 4. Uneven Tire Wear
- Buying a Used 2021-2025 Model S Control Arm
- Cost Comparison (2021-2025 Tesla Model S)
- Replacement Difficulty: 4/5
- Frequently Asked Questions (FAQ)
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