Replace a front brake caliper on a 2024 Tesla Cybertruck Dual Motor AWD. The Cybertruck uses conventional hydraulic friction brakes at the corner, but service requires awareness of its 48V low-voltage architecture and air suspension before lifting.

Warnings

Tools required

Parts

• Front brake caliper assembly (Cybertruck front, correct side) × 1 — Tesla OEM front caliper — confirm left/right by VIN
• Copper crush washers for banjo fitting × 2 — OEM-spec copper sealing washers, banjo size
• Brake pads (inspect; replace if worn or contaminated) × 1 — Cybertruck front pad set
• DOT 3 brake fluid (sealed container) × 1 — DOT 3 per Tesla spec

Fluids

• DOT 3 Brake Fluid — 1 qt

Preparation

1. Park on level ground, place in P, and engage the parking brake.
2. Exit ALL doors with the 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 low-voltage battery. NOTE: Cybertruck uses a 48V low-voltage architecture (not 12V) — follow the Tesla service manual location and disconnect procedure for this vehicle.
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. Enter Service Mode / Jack Mode on the center touchscreen to disable air suspension self-leveling before lifting.
7. Loosen the front wheel lug nuts while the vehicle is on the ground.
8. Lift the vehicle at the manufacturer-specified front jacking points using Tesla-approved lift pucks; support on rated jack stands.
9. Remove the front wheel on the side being serviced.
10. Inspect the brake hose, caliper, rotor, and pads. Confirm side-specific caliper part before opening the hydraulic system.

Procedure

1. 1

   Reduce reservoir fluid level
   Open the brake fluid reservoir cap and use a clean fluid extractor to draw the level down to roughly half. This minimizes spillage when the caliper hose is disconnected. Re-cap loosely to keep contaminants out.
   ⚠Use only fresh DOT 3 from a sealed container; do not reuse extracted fluid.
2. 2

   Position drain pan and crack the banjo bolt
   Place a catch container beneath the caliper. Using the correct wrench, crack loose (do not yet remove) the brake hose banjo bolt at the caliper to confirm it will release before committing to the job.
3. 3

   Remove brake pads (if reusing) and free the caliper from the bracket
   Remove any pad retention hardware per the OEM procedure and slide the pads out, noting orientation. Then remove the two caliper-to-bracket mounting bolts. Support the caliper with a hanger — never let it dangle from the hose.
4. 4

   Disconnect brake hose at caliper
   Fully remove the banjo bolt at the caliper inlet. Capture the two copper crush washers and discard them — new ones are required on reassembly. Cap or plug the open hose to prevent contamination and fluid loss.
   ⚠Do not allow brake fluid to drip onto suspension components, the stainless exoskeleton, or wiring.
5. 5

   Remove caliper and (if required) caliper bracket
   Lift the old caliper away. If the replacement is a complete caliper-and-bracket assembly, also remove the two front caliper bracket bolts from the steering knuckle. Clean the bracket mating surface of corrosion and debris.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
6. 6

   Inspect rotor and related hardware
   Inspect the rotor for scoring, heat checking, and minimum thickness per the OEM specification. Inspect slide pins (if equipped) for free movement and clean grease. Replace any component not within spec before proceeding.
7. 7

   Install caliper bracket (if removed)
   Position the bracket to the knuckle. Apply medium-strength thread locker to the bracket bolt threads and start by hand. Torque to specification.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
8. 8

   Install brake pads and new caliper
   Install new or inspected pads into the bracket per OEM orientation. Mount the new caliper over the rotor and pads. Apply medium-strength thread locker to the caliper mounting bolts and torque to specification.
9. 9

   Reconnect brake hose with new copper washers
   Install the brake hose to the caliper using TWO NEW copper crush washers (one on each side of the banjo fitting). Ensure hose routing is not twisted and clears suspension travel. Torque the banjo bolt to specification.
   ⚠Reusing copper washers will leak. Always use new washers.
10. 10

    Bleed the brake circuit
    Top up the reservoir with fresh DOT 3. Bleed the caliper using the bleeder screw with a vacuum or pressure bleeder until clean, bubble-free fluid flows. Maintain reservoir level throughout — do not let it run dry. Torque the bleeder screw to specification; do not overtighten. Refer to the Tesla Service Manual for the correct bleed sequence for the Cybertruck (which may require Toolbox-initiated ABS/iBooster bleeding for a complete service).
    ℹ️A full system bleed including the booster/ABS module typically requires Tesla Toolbox. If pedal feel is not firm after a manual caliper bleed, stop and have the system bled with the factory tool.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Reinstall wheel
    Mount the wheel and run lug nuts down by hand. Lower the truck until the tire just contacts the ground, then torque the lug nuts in a star pattern to specification.

Reassembly

1. Top off the brake fluid reservoir to the MAX line with fresh DOT 3 and securely close the cap.
2. Lower the vehicle fully to the ground and remove jack stands.
3. Reconnect the 48V low-voltage battery per the Tesla service manual procedure.
4. Exit Jack/Service Mode via the touchscreen so air suspension can resume normal operation.
5. With the vehicle stationary and brake pedal depressed, allow the air suspension to re-level before driving.

Verification

• With the truck powered on and stationary, pump the brake pedal until firm — pedal must not sink to the floor.
• Inspect the banjo fitting and bleeder under pressure for any seepage; recheck after the first short drive.
• Confirm no brake-related alerts (ABS, iBooster, brake fluid level) on the touchscreen.
• Perform low-speed stops in an empty area to bed-in pads and verify even, straight braking with no pull or pulsation.
• Recheck brake fluid level after the first drive and top off to MAX with DOT 3 if needed.
• Note: Tesla recommends a brake fluid service every 2 years regardless of mileage — log the date and consider a full flush if the fluid is near or past that interval.
• If pedal feel is soft or a brake warning is present, do not drive the vehicle — a full bleed using Tesla Toolbox may be required.

More procedures for this vehicle