Tesla Model S: Sway Bar - Front (Dual Motor) (Remove and Replace)

Warning: If the vehicle has air suspension, activate "Jack" mode on the touchscreen before raising and supporting the vehicle.

Warning: If the 12V power supply is disconnected, do not attempt to open any doors with door glass in closed position. Failure to follow this instruction could result in door glass shatter.

Note: Before disconnecting the 12V power supply, ensure that the driver's door window is fully open. Failure to follow this instruction could result in vehicle lockout.

Removal

1. Position the vehicle on a lift, but do not raise it at this time.
2. Remove the underhood storage unit (refer to procedure).
3. Disconnect the first responder loop (X536) Do not cut the loop.
4. Disconnect the 12V battery ground connection (torque 5 Nm).
5. Release the bolts (x2) that secure the steering rack to the subframe (torque 175 Nm).

   

6. Disconnect the harnesses (x3) from the power steering rack.
7. On both sides of the vehicle, remove the bolt that secures the steering brace to the subframe (torque 26 Nm).

   

8. On the RH side of the vehicle, release the fir tree clip that secures the coolant hose to the steering brace.

   

9. Disconnect the harness from coolant pumps 1 and 2, then remove both coolant pumps from the subframe. Note: It is not necessary to disconnect the coolant hoses from the pumps. Note: It is not necessary to remove the rubber isolators from the pumps.
10. Raise the vehicle, then remove the front wheels (refer to procedure).
11. On both sides of the vehicle, remove the lower front wheel arch liner (refer to procedure).
12. On the RH side of the vehicle, remove the condenser fan (refer to procedure). Note: Only perform this step on the RH side of the vehicle.
13. Remove the RH condenser fan control module (refer to procedure).
14. On both sides of the vehicle, restrain the tie rod ball joint pin, then remove the nut that secures the tie rod end to the knuckle (torque 103 Nm).

    Caution: To prevent ball joint damage, always hold the ball joint pin with a wrench while loosening or tightening the lock nut.

    

15. Remove the front aero shield (refer to procedure).
16. Remove the LH and RH front lower control arms (refer to procedure). Note: Do not remove the rear lower control arms.
17. Working from beneath the vehicle, remove the connector from the base of the 3 way valve.

    

18. Release the edge clip that secures the 3 way valve harness to the subframe. Move the harness above the sway bar and out of the working area.

    

19. Note: This step is for air suspension vehicles only. Working from the RH wheelwell, remove the bracket that secures the air suspension lines to the side rail.
20. Working in the LH wheelwell, release the cable ties (x2) that secure the fan control module harness to the side rail.

    

21. Remove the nuts (x2) that secure the A/C line to the side rail (torque 5.5 Nm).

    

22. On the RH side of the vehicle, loosen the bolt that secures the steering brace to the base of the side rail (torque 26 Nm), then remove the brace.

    Note: Do not remove the bolt.

    

23. Note: This step is for air suspension vehicles only. On the LH side of the vehicle, release the clip that secures the air suspension line to the steering brace.

    

24. Repeat step 22 to remove the LH steering brace.
25. On both sides of the vehicle, remove and discard the bolt that secures the sway bar to the sway bar end links (torque 70 Nm).  

    

26. On both sides of the vehicle, remove and discard the bolt that secures the sway bar bracket to the base of the side rail (torque 115 Nm).  

    

27. Working from the RH wheelwell, rotate the sway bar forward.

    

    Note: The bar rotates freely until the LH sway bar bracket is blocked by the subframe.

    

28. Use a pry bar to provide clearance between the subframe and LH sway bar bracket.

    Caution: Do not damage the subframe.

    

29. Continue rotating the sway bar forward. Ensure that:
    • The sway bar does not damage the A/C line on the LH side rail.

      

    • Air suspension vehicles only: The sway bar does not damage the air suspension lines on the RH side rail.

      

30. On both sides of the vehicle, pivot the sway bar bracket over the tie rod.

    Caution: Do not damage the tie rod boot.

    

31. Working from the RH wheelwell, push the sway bar inboard and route it underneath the coolant hose.

    

32. Working from the LH wheelwell, pull the sway bar outboard. Caution: Have an assistant stand beneath the center of the vehicle and guide the sway bar as it is removed to ensure that no harnesses or hoses are damaged.
33. Maneuver the LH sway bar bracket so that it does not damage the coolant hose, harness, or air suspension line (if equipped).

    

    1	Coolant hose
    2	Harness
    3	Air suspension line

34. Completely remove the sway bar from the vehicle.

    

1. Reinstall the front sway bar. Installation is the reverse of removal, except for the following:
   • During reinstallation, first pivot the LH sway bar bracket below the LH tie rod.
   • Air suspension vehicles only: While rotating the bracket back into its installation position, ensure that the air suspension lines on both sides of the vehicle are inboard of the the sway bar.

     

   • If necessary, use a pry bar to move the RH side of the sway bar underneath the subframe.

     

   • Replace the nuts that secure the sway bar to the end links.
   Caution: Do not fully torque the front control arms to the subframe at this time. They must be torqued at ride height in a later step.

   Caution: Do not damage the subframe or sway bar.

2. Lower the vehicle to ride height.
3. Fully torque the front control arms to the subframe (torque 130 Nm).
4. Perform a four wheel alignment (refer to procedure).

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