Rebuild of the front brake calipers on a 2024 Tesla Cybertruck Cyberbeast. This procedure covers caliper removal, disassembly, seal replacement, and reinstallation with proper torque and bleeding. Note that Tesla recommends brake fluid replacement every 2 years regardless of mileage — perform that service alongside this rebuild.

Warnings

Tools required

Parts

• Front brake caliper rebuild kit (piston seals, dust boots, bleeder cap) × 2 — OEM Cybertruck front caliper seal kit — refer to Tesla Service Manual
• Caliper slide pin boots (if not included in seal kit) × 2 — OEM specification
• Silicone brake grease (caliper-rated) × 1 — OEM specification
• Brake cleaner (chlorinated or non-chlorinated, non-residue) × 2 — Generic
• Copper crush washers for brake hose banjo (if equipped) × 4 — OEM specification
• Threadlocker (medium-strength, blue) × 1 — Loctite 243 or equivalent

Fluids

• DOT 3 Brake Fluid (Tesla-specified) — 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 per Tesla service procedure (NOT 12V — Cybertruck uses 48V architecture; many connectors and disconnect procedures differ from other Teslas). Refer to Tesla Service Manual for exact 48V disconnect location and sequence.
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. Enable Service Mode / Jack Mode on the touchscreen BEFORE disconnecting low-voltage power — this disables the air suspension self-leveling and prevents the vehicle from rising during service.
7. Loosen front wheel lug nuts while the vehicle is still on the ground.
8. Lift the front of the vehicle using Tesla-approved lift points only and support on heavy-duty jack stands rated for Cybertruck weight.
9. Remove front wheels and set aside on a non-marring surface.
10. Position a drain pan beneath the work area to catch brake fluid.
11. Inspect the rotor, pads, hose, and bracket for damage before disassembly — replace any component outside spec.

Procedure

1. 1

   Clamp brake hose and disconnect from caliper
   Clamp the flexible front brake hose with a brake hose clamp to minimize fluid loss. Place a drain pan under the caliper. Loosen and remove the brake hose fitting (banjo bolt or threaded fitting per OEM design) at the caliper. Cap the hose immediately to prevent contamination and air ingress. Discard old crush washers if a banjo-style fitting is used.
   ⚠Do not allow brake fluid to contact the stainless body or painted suspension components.
2. 2

   Remove brake pads and caliper
   Remove the caliper guide pin bolts (slide pin bolts) and lift the caliper body off the bracket. Slide brake pads out of the bracket. Inspect pads — replace if below minimum thickness specified in the Tesla Service Manual.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Remove caliper mounting bracket from knuckle
   Unbolt the caliper bracket from the steering knuckle. These bolts are CRITICAL torque fasteners and were installed with threadlocker. Bag and label hardware. Inspect bolt threads for damage; replace if compromised.
   ⚠Caliper bracket bolts are critical fasteners. Do not reuse damaged bolts — torque integrity affects braking safety.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
4. 4

   Extract caliper piston(s)
   Move the caliper to a clean bench. Place a wood block in the caliper opening to cushion the piston(s). Use low-pressure compressed air at the brake fluid inlet port to gently push the piston(s) out of the bore. Apply pressure gradually — pistons can eject suddenly. If pistons are seized, follow Tesla Service Manual procedure for hydraulic extraction.
   ⚠️Keep fingers clear of the piston bore during air extraction — pistons can launch with force capable of crushing fingers.
5. 5

   Remove dust boots and piston seals
   Carefully remove dust boots from the caliper bore. Using a non-metallic pick, extract the square-cut piston seals from the seal grooves in the bore. Take care not to scratch or gouge the bore surface — any scoring will cause future leaks.
   ⚠Never use a metal pick directly against the seal groove — bore damage is not repairable and requires full caliper replacement.
6. 6

   Clean and inspect caliper components
   Thoroughly clean the caliper body, bore, and pistons with brake cleaner. Inspect the bore for pitting, scoring, or corrosion. Inspect pistons for chrome plating damage, pitting, or discoloration. Replace any piston or caliper that shows damage — do not attempt to polish bore or piston surfaces. Clean slide pins and bores; inspect for wear.
7. 7

   Install new piston seals and dust boots
   Lubricate new piston seals with clean DOT 3 brake fluid. Install seals into the bore grooves, ensuring they sit flat and untwisted. Install new dust boots into their grooves per the OEM-specified orientation. Lubricate piston exterior with clean brake fluid.
8. 8

   Reinstall pistons into caliper
   Carefully push each piston straight into its bore by hand, working slowly to avoid damaging the new seal. Use a piston compression tool only if the bore design permits — do not force a cocked piston. Seat the dust boot fully onto the piston groove around its full circumference.
   ⚠A pinched or rolled dust boot will allow contamination and cause repeat failure. Verify boot seating visually around the entire circumference.
9. 9

   Service slide pins
   Clean the slide pins and bracket bores. Apply silicone brake grease to the slide pins. Reinstall slide pin boots if replaced. Reinsert pins into the bracket and verify smooth, full-stroke movement.
10. 10

    Reinstall caliper bracket to knuckle
    Apply medium-strength threadlocker to the caliper bracket bolts. Install the bracket onto the steering knuckle and torque the bolts to specification in a cross pattern. These are CRITICAL fasteners.
    Torque spec

    Bracket Bolts102 Nm (75 lb-ft)
11. 11

    Install pads and caliper
    Insert brake pads into the bracket with anti-rattle hardware in the correct orientation. Position the caliper over the pads and rotor. Install the caliper slide pin bolts and torque to specification. Apply silicone brake grease to slide pins as noted.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
12. 12

    Reconnect brake hose
    Reconnect the brake hose to the caliper using NEW crush washers if a banjo fitting is used. Torque the hose fitting to OEM specification — refer to Tesla Service Manual. Remove the brake hose clamp.
    ⚠Always replace crush washers — reused washers will weep brake fluid.
13. 13

    Bleed brake system
    Refill the brake fluid reservoir with fresh DOT 3 fluid. Bleed each caliper using the bleeder screw, following the Tesla-specified bleed sequence for Cybertruck. On steer-by-wire/brake-by-wire equipped Tesla vehicles, an electronic bleed routine via diagnostic tool may be required to fully purge the ABS/iBooster module — refer to Tesla Service Manual. Torque bleeder screws carefully — do not overtighten.
    ⚠Cybertruck brake system may require a scan-tool-initiated electronic bleed to purge the hydraulic control unit. Manual bleeding alone may leave air in the system.
    ℹ️Tesla recommends brake fluid replacement every 2 years regardless of mileage. Performing a full flush at this time satisfies that interval.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)

Reassembly

1. Verify all fasteners are torqued to specification.
2. Top off brake fluid reservoir to the MAX line with fresh DOT 3.
3. Reinstall front wheels. Hand-thread lug nuts before lowering.
4. Lower vehicle to the ground.
5. Torque wheel lug nuts in a star pattern to specification.
6. Reconnect the 48V low-voltage battery per Tesla procedure.
7. Exit Service/Jack Mode via the touchscreen and allow the air suspension to re-level.

Verification

• With the vehicle awake but stationary, pump the brake pedal until firm — pedal should not sink to the floor.
• Inspect the caliper, hose fitting, and bleeder screw for any sign of brake fluid weeping after pedal pressurization.
• Confirm brake fluid reservoir level remains at MAX.
• Check the touchscreen for any brake system, ABS, or stability control alerts. Cybertruck's brake-by-wire integration may require a diagnostic scan tool to clear residual codes after bleeding.
• Perform a low-speed (5–10 mph) brake test in a safe area to verify pedal feel and even braking. Listen for any drag, pulling, or unusual noise.
• Gradually increase test speed to 30–40 mph with progressive braking to confirm normal stopping behavior before returning the vehicle to service.
• Re-check lug nut torque after the first 50 miles of driving.
• Log this service date — Tesla recommends brake fluid service every 2 years regardless of mileage; next inspection due in 24 months.

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