Replace a front brake hose on a 2024 Tesla Model 3 Performance. This job involves opening the hydraulic system, so brake fluid bleeding is required after installation.

Warnings

Tools required

Parts

• Front brake hose (manufacturer-specified for Model 3 Performance) × 1 — Tesla OEM front brake hose — verify by VIN
• Copper sealing washers for banjo fitting × 2 — New crush washers, banjo bolt size
• Brake hose retaining clip (if damaged on removal) × 1 — OEM hose-to-strut retaining clip

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 (or Li-ion low-voltage) battery. On 2024 Model 3, the low-voltage battery is typically located behind the right rear seat back panel or under the rear floor — refer to architecture notes and confirm by VIN.
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 is NOT required for this job, but if available, use it to suspend air suspension/regen behavior (N/A on Model 3 — coil only).
7. Chock the rear wheels. Loosen front lug nuts while tires are on the ground.
8. Raise the front of the vehicle using only Tesla-designated lift points with rubber jack pucks to avoid damaging the battery pack edge or pinch welds.
9. Support the vehicle on jack stands and remove both front wheels (or just the affected side, if working one side).
10. Open the brake fluid reservoir cap briefly to release pressure, then re-cap to limit fluid loss; place absorbent rags below the work area.

Procedure

1. 1

   Inspect and pre-clean fittings
   Clean the banjo fitting at the caliper and the hard-line-to-hose junction at the strut bracket with brake cleaner. Inspect the hose for the failure point and confirm the replacement hose matches length and end fittings.
2. 2

   Clamp or plug the hose to limit fluid loss
   Apply a rubber-jawed brake hose clamp to the flexible section of the old hose to minimize reservoir drain-down. Do not clamp the new hose during install.
   ⚠Do not over-clamp; metal-jawed clamps can damage internal liners. Only use a proper brake hose pinch tool.
3. 3

   Disconnect the hard line from the hose
   At the strut/frame bracket, hold the hose hex with one wrench and use a flare-nut/line wrench to loosen the hard line fitting. Cap the hard line immediately to prevent contamination.
   ⚠Use a flare-nut wrench only — open-end wrenches will round the soft fitting.
   Torque spec

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

   Release the hose from the chassis bracket
   Remove the U-clip retainer securing the hose end to the chassis/strut bracket. Pull the hose end downward through the bracket. Inspect the clip for damage; replace if bent.
5. 5

   Disconnect the banjo bolt at the caliper
   Position a catch container under the caliper. Remove the banjo bolt from the caliper inlet. Discard the two copper sealing washers — they are single-use. Allow residual fluid to drain.
   ⚠Brake fluid will run down the caliper and rotor. Wipe the rotor immediately with brake cleaner before reinstallation; contaminated pads/rotors must be replaced.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
6. 6

   Remove the old hose
   Free the hose from any intermediate routing clips along the strut. Note the orientation of the banjo end (alignment tang/locator) — the new hose must be installed in the same orientation to prevent contact with suspension components at full lock and full droop.
   ⚠Incorrect hose clocking can cause contact with the tire or strut at full steering lock — verify clearance through the full steering and suspension range before final torque.
7. 7

   Install the new hose at the caliper
   Place a new copper washer on each side of the banjo eyelet. Thread the banjo bolt into the caliper by hand. Set the hose orientation against its locator tang, then torque to specification.
   ⚠Always use NEW copper washers — reusing washers will cause weeping leaks.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
8. 8

   Secure the hose to the chassis bracket and connect the hard line
   Insert the hose end through the chassis/strut bracket and install the U-clip fully seated. Hand-thread the hard line fitting into the hose end first to avoid cross-threading, then torque the line fitting using a flare-nut wrench. If the bracket fastener was disturbed, torque it to spec.
   ⚠Verify hose is not twisted. The hose should follow a natural arc with no kinks at full lock left or right.
   Torque spec

   Line Fittings20 Nm (15 lb-ft)

   Brake Hose Bracket10 Nm (7 lb-ft)
9. 9

   Verify routing through full suspension/steering travel
   With the wheel still off, manually cycle the steering lock-to-lock and observe hose clearance to the tire, strut, wheel speed sensor harness, and any underbody components. Re-clock the banjo if needed.
10. 10

    Bleed the front brake circuit
    Top off the reservoir with fresh DOT 4 brake fluid. Bleed the affected caliper at the bleeder screw using a vacuum bleeder or two-person pedal method until clear, bubble-free fluid flows. Keep the reservoir above MIN throughout. On Model 3, full ABS module bleed requires Tesla service software — a manual bleed is sufficient if no air entered the master cylinder/ABS module.
    ⚠If the reservoir was allowed to run dry, or if pedal feel remains spongy, an ABS/iBooster bleed via Tesla Toolbox is required — this is dealer-only.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
11. 11

    Final leak check
    Have an assistant apply firm, steady pedal pressure (approx. 30 seconds) while you inspect the banjo, hose body, and hard line connection for any weeping. Wipe joints dry and re-check after a second pedal application.

Reassembly

1. Reinstall the front wheel(s). Hand-thread all lug nuts before applying torque.
2. Lower the vehicle to the ground.
3. Torque the wheel lug nuts in a star pattern to specification.
4. Top off the brake fluid reservoir to the MAX line with fresh DOT 4 fluid and reinstall the cap.
5. Reconnect the 12V/Li-ion low-voltage battery and reinstall any trim removed for access.
6. Allow the vehicle to wake (open driver door with fob), and confirm the touchscreen boots normally with no brake or ABS warnings.

Verification

• With the vehicle on, pedal should be firm on the first press — no sponginess or sink.
• No brake warning, ABS, or traction control indicators on the touchscreen instrument cluster.
• Perform a low-speed (10-15 mph) brake test in an empty area. Pedal feel should match the opposite (untouched) side; the car should brake straight with no pull.
• Re-inspect the banjo and line fittings for leaks after the test drive.
• Verify hose clearance one more time at full steering lock, both directions.
• Reminder: Tesla recommends a full brake fluid flush every 2 years. If the vehicle is due, consider completing a full system bleed now while the system is open.
• If pedal remains soft after manual bleed, schedule a Tesla service appointment for an ABS/iBooster bleed using Tesla Toolbox — this cannot be performed without factory software.

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