Brake Caliper Rebuild - Rear

Rebuild of the rear brake calipers on a 2024 Tesla Cybertruck Cyberbeast Tri Motor. This involves removing the calipers, disassembling for piston/seal replacement, cleaning, reassembly with fresh seals, and bleeding the brake hydraulic system.

Warnings

Tools required

Parts

• Rear brake caliper rebuild kit (piston seals, dust boots, bleeder caps) × 2 — OEM Cybertruck rear caliper rebuild kit — refer to Tesla Service Manual
• Caliper slide pin boots (if not included in rebuild kit) × 2 — OEM specification
• Silicone brake grease (caliper-rated) × 1 — Brake-rated silicone grease
• Brake cleaner (chlorinated or non-chlorinated, non-residue) × 1 — Generic
• Threadlocker (medium strength, blue) — if specified by service manual × 1 — Loctite 243 or equivalent

Fluids

• DOT 3 Brake Fluid (Tesla specification) — 1 qt

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 48V low-voltage battery (Cybertruck uses 48V LV, NOT 12V). Refer to the Tesla Service Manual for the 48V LV battery location and disconnect procedure on Cybertruck.
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage (800V on Cybertruck) 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. Enter Service Mode and engage Jack Mode via the touchscreen to disable air suspension self-leveling and brake actuator self-test cycles.
7. Disable Sentry Mode and close the frunk/bed cover access if applicable.
8. Loosen rear wheel lug nuts while wheels are on the ground.
9. Lift the rear of the vehicle using Tesla-approved jack points and support securely on jack stands rated for Cybertruck weight.
10. Remove rear wheels and set aside.
11. Place a drain pan beneath the work area to catch brake fluid.

Procedure

1. 1

   Inspect and prepare the rear caliper area
   Visually inspect the rear caliper, brake hose, bleeder, and pad wear. Photograph routing of any electronic parking brake (EPB) wiring/connector and brake hose orientation for reassembly reference. Clean exterior of caliper with brake cleaner.
2. 2

   Retract the electronic parking brake (EPB)
   The Cybertruck rear calipers incorporate an electronic parking brake actuator. Using Tesla Service Mode, place the EPB into Service/Maintenance Mode to fully retract the parking brake actuator. Do NOT attempt to manually unwind the EPB motor — damage to the gearset will result. Disconnect the EPB electrical connector at the caliper after retraction.
   ⚠Failing to put the EPB in service mode before attempting piston retraction will damage the actuator and may require caliper replacement.
3. 3

   Clamp brake hose and disconnect hydraulic line
   Clamp the rubber section of the brake hose with a rubber-jaw hose clamp to minimize fluid loss. Place a drain pan beneath the caliper. Loosen and disconnect the brake hose banjo bolt or threaded fitting at the caliper. Cap the hose end immediately to prevent contamination. Discard sealing washers if a banjo fitting is used — replace with new ones at reassembly.
   ⚠Do not allow brake fluid to contact the stainless exoskeleton or painted/anodized components.
4. 4

   Remove caliper from bracket
   Remove the caliper slide/guide pin bolts holding the caliper body to the bracket. Slide the caliper off the rotor and pads. Place caliper on a clean bench. Remove brake pads and note inboard/outboard orientation and any wear-sensor wiring routing.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
5. 5

   Remove caliper bracket (if needed for rebuild access)
   If the rebuild requires bracket removal for cleaning or slide pin service, remove the two caliper bracket bolts securing the bracket to the rear knuckle. Inspect bracket for cracks or corrosion.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
6. 6

   Disassemble caliper — remove pistons
   With the caliper on the bench, place a wood block inside the caliper cavity to cushion piston ejection. Apply LOW-pressure compressed air to the fluid inlet port to walk pistons out evenly. Keep fingers clear. If one piston pops first, plug it with a rubber stopper and continue on the remaining piston.
   ⚠️Compressed air can eject pistons forcefully — never place fingers between piston and caliper body. Use minimum pressure required.
7. 7

   Remove dust boots and piston seals
   Carefully remove dust boots from the caliper bore. Using a non-metallic pick, extract the square-section piston seals from the bore grooves. Do NOT scratch the bore — any scoring on the sealing surface requires caliper replacement.
   ⚠Bore scoring is not repairable. Inspect carefully — if scored, replace the caliper assembly.
8. 8

   Clean and inspect components
   Clean caliper body, bores, and pistons with fresh brake cleaner and lint-free towels. Inspect pistons for pitting, corrosion, or chrome flaking — replace any damaged piston. Inspect bores for corrosion. Use a brass brush only on non-sealing surfaces. Blow out internal passages with compressed air. Inspect slide pins, lubricate sliding surfaces with silicone brake grease, and replace torn boots.
9. 9

   Install new seals and reassemble pistons
   Lubricate new piston seals with clean DOT 3 brake fluid and install into bore grooves, ensuring they sit flat and untwisted. Install new dust boots per manufacturer orientation. Lubricate piston walls with clean brake fluid and carefully press pistons squarely back into bores using a piston compression tool — never cock the piston. Seat dust boot lip into the piston groove.
   ⚠Never use mineral oil, petroleum grease, or non-brake-rated lubricants on internal seals — they will swell and destroy the rubber.
10. 10

    Reinstall caliper bracket and caliper
    If removed, reinstall the caliper bracket to the knuckle. Apply threadlocker to bracket bolts if specified by Tesla Service Manual. Torque bracket bolts to specification. Install brake pads with anti-rattle clips/shims as originally configured. Slide caliper over the rotor onto the bracket. Apply silicone brake grease to slide pins and torque slide pin bolts.
    Torque spec

    Bracket Bolts102 Nm (75 lb-ft)

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
11. 11

    Reconnect hydraulic line and EPB connector
    Reconnect the brake hose to the caliper using NEW sealing washers (if banjo style). Torque the fitting to OEM specification — refer to Tesla Service Manual. Reconnect the EPB electrical connector and ensure routing matches original. Remove the hose clamp.
12. 12

    Bleed the brake system
    Top off the master cylinder reservoir with fresh DOT 3 brake fluid. Tesla Cybertruck uses an electronically actuated brake system; full bleeding typically requires Tesla Service Mode bleed procedure to cycle the brake actuator. Perform a manual bleed at the rear caliper bleeder screw first (farthest from master cylinder side per Tesla bleed sequence — refer to Service Manual), then run the Service Mode automated bleed routine. Continue until clear, bubble-free fluid flows from each bleeder. Maintain reservoir level throughout — never let it run dry.
    ⚠Allowing the master cylinder reservoir to run dry will introduce air into the actuator and may require a Tesla Toolbox bleed procedure to recover.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
13. 13

    Recalibrate the EPB
    Using Tesla Service Mode, exit EPB Service Mode and run the parking brake calibration/initialization routine. Confirm the EPB applies and releases without faults.

Reassembly

1. Reinstall rear wheels. Hand-thread all lug nuts.
2. Lower vehicle to ground.
3. Torque wheel lug nuts to specification in a star pattern.
4. Reconnect the 48V low-voltage battery per Tesla procedure.
5. Exit Jack Mode and Service Mode via the touchscreen.
6. Top off brake fluid reservoir to MAX line with fresh DOT 3 fluid.
7. Verify reservoir cap is fully seated.

Verification

• With vehicle stationary and ignition on, pump the brake pedal — pedal should be firm and consistent, not spongy.
• Check for any brake fluid leaks at caliper, hose fitting, and bleeder screws.
• Confirm no ABS, EPB, or brake system warning messages on the touchscreen.
• Engage and release the parking brake several times via the touchscreen — listen for proper actuator cycling and confirm no faults.
• Perform low-speed test drive in a safe area: light brake application first, then progressively firmer, listening for noise and confirming straight, even stopping.
• Re-check torque on lug nuts after 50 miles (Tesla recommendation).
• Inspect for leaks again after first drive.
• Note: Tesla recommends brake fluid replacement every 2 years — log this service date and schedule the next flush accordingly.
• Note: Tesla recommends tire rotation every 6,250 mi — consider performing while wheels are off.

Related trouble codes on this vehicle

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