Brake Caliper Rebuild - Rear

Rebuild of the rear brake calipers on a 2024 Tesla Cybertruck Dual Motor AWD. This involves removing the calipers, replacing seals/pistons with a rebuild kit, and bleeding the brake system with DOT 3 fluid.

Warnings

Tools required

Parts

• Rear brake caliper rebuild kit (piston seals, dust boots, bleeder caps) × 2 — OEM-specified Cybertruck rear caliper rebuild kit
• Caliper slide pin boots (if included separately) × 2 — OEM-specified
• Replacement caliper bolts (if single-use per Tesla spec) × 4 — OEM-specified — verify reuse policy in Tesla Service Manual
• Copper crush washers for brake hose banjo (if applicable) × 2 — OEM-specified

Fluids

• DOT 3 Brake Fluid — 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's Cybertruck-specific procedure (NOT the standard 12V Tesla procedure — connectors and location differ on Cybertruck).
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal on the 800V pack.
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. On the touchscreen, enable Service Mode and place the EPB in 'Brake Service' / retract position to fully back off the parking brake actuator.
7. Place the air suspension in Jack Mode via the touchscreen.
8. Loosen rear lug nuts while wheels are on the ground, then lift the vehicle and support on rated jack stands. Remove rear wheels.
9. Have a catch pan and rags ready for brake fluid.

Procedure

1. 1

   Disconnect EPB actuator
   Locate the electric parking brake actuator wiring harness on the rear caliper. Release the connector lock and unplug. Secure the harness aside so it is not strained during caliper removal.
   ⚠Confirm EPB has been retracted via Service Mode. Disconnecting under load can damage the actuator gear train.
2. 2

   Disconnect brake hydraulic line
   Place a catch pan under the caliper. Using a flare-nut/line wrench, loosen the brake line fitting at the caliper. Cap the line immediately to minimize fluid loss and contamination. Replace any crush washers on reassembly.
   ⚠Use a line wrench only — open-end wrenches will round the fitting.
   Torque spec

   Line Fittings20 Nm (15 lb-ft)
3. 3

   Remove caliper from bracket
   Remove the two caliper guide/slide pin bolts holding the caliper body to the bracket. Lift the caliper off the rotor and brake pads. Inspect slide pins and boots for damage.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
4. 4

   Remove brake pads and bracket (optional for full rebuild)
   Slide the brake pads out of the bracket. If replacing the bracket or accessing the rotor, remove the two bracket-to-knuckle bolts. Otherwise, leave the bracket installed.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
5. 5

   Extract caliper pistons
   With the caliper on a bench, place a wood block in the pad cavity and use low-pressure compressed air at the fluid inlet to push the piston(s) out. For the EPB-integrated piston, follow the manufacturer-specified procedure — some require unscrewing via the actuator drive shaft. Catch the piston with the wood block to prevent damage.
   ⚠️Keep fingers clear of the piston bore — pistons can eject with force and amputate fingertips.
   ⚠The rear caliper piston interfaces with the EPB screw mechanism. Do not damage the threaded spindle.
6. 6

   Remove dust boot and piston seal
   Carefully pry off the outer dust boot. Using a non-metallic seal pick, remove the square-cut piston seal from the groove inside the bore. Do not scratch the bore — any scoring will cause fluid leakage.
   ⚠Use only plastic or brass picks. Steel picks will gouge the aluminum bore.
7. 7

   Clean and inspect caliper body
   Clean the caliper body, bore, and piston with fresh DOT 3 brake fluid or denatured alcohol — never petroleum solvents. Inspect the bore for pitting, scoring, or corrosion. Inspect the piston for plating damage. Replace the caliper assembly if either is compromised.
   ⚠Petroleum-based cleaners (brake parts cleaner with chlorinated solvents) will swell rubber seals — use only brake-safe cleaner on rubber components.
8. 8

   Install new piston seal and dust boot
   Lubricate the new square-cut seal with clean DOT 3 brake fluid and seat it evenly in its groove. Install the new dust boot onto the piston. Coat the piston with brake fluid and carefully insert it straight into the bore. Seat the dust boot onto the caliper lip.
   ⚠Do not use silicone grease or assembly lube on internal sealing surfaces — only clean DOT 3 brake fluid.
9. 9

   Service slide pins
   Clean slide pins and bores. Replace torn boots. Apply silicone brake grease to slide pins before reinsertion. Verify pins move freely with no binding.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Reset EPB piston (if applicable)
    If the EPB piston was extended/threaded out, retract it fully back into the bore using the manufacturer-specified procedure. Confirm the piston is at its full home position before installing pads.
    ⚠Failure to fully retract the EPB piston will prevent the caliper from clearing the rotor and pads.

Reassembly

1. If removed, reinstall the caliper bracket to the knuckle with new threadlocker if specified, and torque the bracket bolts.
2. Install brake pads into the bracket with anti-rattle clips properly seated.
3. Apply medium-strength threadlocker to the caliper slide pin bolts. Reinstall the caliper over the rotor and pads. Torque the slide pin bolts.
4. Reconnect the brake line with new crush washers (if used). Torque the line fitting using a line wrench — do not overtighten.
5. Reconnect the EPB actuator electrical connector and verify the lock clicks fully.
6. Reinstall the wheel and hand-thread all lug nuts. Lower the vehicle until tires just touch the ground, then torque lug nuts in a star pattern.
7. Bleed the brake system at all four corners using DOT 3 fluid, starting at the corner farthest from the master cylinder. Torque bleeder screws — do not overtighten.
8. Reconnect the 48V low-voltage battery using the Cybertruck-specific procedure.
9. Exit Jack Mode and Service Mode on the touchscreen. Re-calibrate the EPB through Service Mode (apply/release cycle) per Tesla procedure.

Verification

• With the vehicle off, pump the brake pedal until firm — pedal should not sink under sustained pressure.
• Check for fluid leaks at the caliper line fitting, bleeder screw, and piston dust boot after the first pedal pressurization.
• Use the touchscreen Service Mode to cycle the EPB apply/release several times. Confirm no fault codes are present.
• Perform a low-speed (5–10 mph) brake test in a safe, empty area. Listen for dragging or pulling.
• Drive at moderate speed and perform several controlled stops to bed in the pads. Inspect for even pad contact on the rotor.
• Recheck brake fluid level at the reservoir after the test drive and top off with DOT 3 if needed.
• Note: Tesla recommends a full brake fluid change every 2 years regardless of mileage — log this service date for the owner.

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