Replacement of a front brake hose on a 2024 Model 3 Long Range AWD. The job involves opening the hydraulic system, so brake fluid bleeding is required afterward.

Warnings

Tools required

Parts

• Front brake hose (left or right as applicable) × 1 — OEM Tesla Model 3 front brake hose — verify side
• Copper sealing washers for banjo fitting × 2 — OEM-spec copper crush washers (typically 2 per banjo)

Fluids

• DOT 4 Brake Fluid (Tesla specification) — 1 qt

Preparation

1. Park on level ground, place in P, engage 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 12V low-voltage battery. On 2024 Model 3, the low-voltage battery may be a lithium unit located under the floor or behind interior trim — refer to the architecture notes and confirm location before disconnecting.
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. Place Service Mode considerations aside — this job does not require Toolbox, but disabling the vehicle via the touchscreen 'Service Mode' (if available to you) can prevent unintended brake actuation during the procedure.
7. Loosen the front wheel lug nuts on the affected side while the wheel is still on the ground.
8. Lift the vehicle at the manufacturer-specified front jack point using a puck adapter; support on jack stands.
9. Remove the front wheel.
10. Top off the brake fluid reservoir (located under the front trunk/frunk panel) to MAX before opening the system, and have a catch pan ready.
11. Inspect the routing of the existing brake hose, noting bracket positions and clip orientations for reinstallation.

Procedure

1. 1

   Clean the fittings
   Spray brake cleaner around the upper hard-line-to-hose junction and the lower banjo fitting at the caliper. Wipe clean. Contamination entering the hydraulic system can damage the iBooster/ABS unit.
2. 2

   Pinch off the hose (optional)
   If using a brake-safe hose clamp, gently pinch the rubber section of the hose to limit fluid loss while disconnecting. Do not clamp on a stainless braided or hard section.
   ⚠Do not over-clamp — internal hose damage from excessive pinching can cause failure after reinstallation if the wrong hose is clamped.
3. 3

   Disconnect the upper hard line
   Using a flare/line wrench, loosen the hard-line fitting at the top of the brake hose where it meets the chassis-mounted bracket. Hold the hose hex with a backup wrench to prevent the hose from twisting. Allow fluid to drip into the catch pan.
   ⚠Use a line wrench only — open-end wrenches will round the soft hard-line fitting.
   Torque spec

   Line Fittings20 Nm (15 lb-ft)
4. 4

   Release the hose from the chassis bracket
   Remove the retaining clip securing the hose fitting to the chassis-mounted bracket. Set the clip aside; if bent or corroded, replace with a new manufacturer-specified clip.
5. 5

   Remove any intermediate hose bracket fasteners
   If the hose is secured by a mid-span bracket bolt to the strut or chassis, remove that fastener now. Note orientation for reinstallation.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
6. 6

   Remove the banjo bolt at the caliper
   Place a catch pan under the caliper. Remove the banjo bolt securing the lower end of the brake hose to the caliper. Discard both copper crush washers — they must not be reused.
   ⚠Cap the caliper port immediately with a clean plug or rag to prevent contamination ingress.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
7. 7

   Remove the old hose
   Withdraw the hose, noting its routing path through any guides or shields. Compare the new hose side-by-side with the old one to confirm correct length, fitting orientation, and bracket tab positions.
8. 8

   Install the new hose at the caliper
   Place a NEW copper crush washer on each side of the banjo fitting. Thread the banjo bolt into the caliper by hand, then torque to specification. Ensure the hose is not twisted and the banjo orientation matches the original.
   ⚠A twisted hose will chafe at full steering lock or full suspension droop and fail prematurely.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
9. 9

   Secure the hose to the chassis bracket
   Seat the upper hose fitting into the chassis bracket and install the retaining clip fully. Verify the hose cannot rotate or pull out.
10. 10

    Reconnect the hard line
    Thread the hard-line fitting into the hose end by hand to avoid cross-threading, then snug with a line wrench. Torque to specification while holding the hose hex with a backup wrench.
    Torque spec

    Line Fittings20 Nm (15 lb-ft)
11. 11

    Reinstall any intermediate bracket hardware
    Reinstall mid-span hose bracket fasteners and torque to specification. Confirm the hose routes cleanly with no contact against suspension or steering components.
    Torque spec

    Brake Hose Bracket10 Nm (7 lb-ft)
12. 12

    Bleed the front brake circuit
    Top off the reservoir with fresh DOT 4 brake fluid. Bleed the front caliper at the bleeder screw until clear, bubble-free fluid flows. Use a pressure bleeder or two-person pedal method. Maintain reservoir level above MIN throughout. Torque the bleeder screw to specification when finished.
    ⚠Tesla's iBooster/ABS may require a Toolbox-assisted bleed to fully purge the HCU if the pedal remains spongy after a manual bleed. If you cannot achieve a firm pedal, do not drive the vehicle — have it bled by a Tesla-certified technician.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)

Reassembly

1. Verify all fittings are torqued and the hose has no twists or contact points through full steering sweep.
2. Top off the brake fluid reservoir to MAX with fresh DOT 4.
3. Reinstall the front wheel; hand-thread all lugs before applying torque.
4. Lower the vehicle to the ground.
5. Torque wheel lug nuts in a star pattern to specification.
6. Reconnect the 12V low-voltage battery.
7. Close the frunk and clean any spilled brake fluid with water.

Verification

• With the vehicle still stationary and the 12V reconnected, press the brake pedal firmly several times — pedal must be firm and not sink under steady pressure.
• Inspect the banjo fitting, hard-line fitting, and bleeder screw for any seepage after pedal pressure tests.
• Power on the vehicle and check the touchscreen for any brake system, ABS, or traction control alerts. Address any faults before driving.
• Turn the steering wheel lock-to-lock and visually confirm the new hose does not contact tire, suspension, or body components at any point.
• Perform a low-speed brake test in a safe area (under 10 mph) before normal driving — confirm straight stops and no pulsing.
• Re-inspect the fittings for leaks after the first short drive.
• Note: Tesla recommends brake fluid replacement every 2 years. Record this service date — if a full flush was performed, reset your maintenance log accordingly.
• Wheel lug nuts: re-torque to specification after approximately 50 miles of driving.
• Torque references for final torque check: Wheel Lug Nuts, Caliper Bolts (if disturbed), Bracket Bolts (if disturbed).

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