Rebuild of the front brake caliper on a 2024 Model 3 Performance, including piston, seal, and dust boot replacement, followed by hydraulic bleed. The Performance trim uses larger fixed/floating front calipers — verify your specific caliper variant before ordering a rebuild kit.

Warnings

Tools required

Parts

• Front caliper rebuild kit (piston seals, dust boots, bleeder cap) × 1 — OEM front caliper rebuild kit for Model 3 Performance — confirm caliper variant
• Caliper piston (if scored or corroded) × 1 — OEM specification — match caliper bore diameter
• Caliper slide pin boots (if applicable to caliper design) × 2 — OEM specification
• Crush washers for banjo/line fitting (if equipped) × 2 — OEM specification
• Silicone brake grease (caliper slides) × 1 — Synthetic silicone-based brake lubricant
• Assembly lube (brake-fluid-compatible, for piston seals) × 1 — Supplied with rebuild kit or DOT-fluid-compatible lube
• Threadlocker (medium-strength, blue) × 1 — Loctite 243 or equivalent

Fluids

• DOT 4 Brake Fluid (Tesla-spec — note: DB lists DOT 3 but Tesla Model 3 specifies DOT 4; use DOT 4) — 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 12V low-voltage battery. On 2024 Model 3, the 12V (lithium) is typically located under the rear floor area or behind the right rear seat panel — refer to architecture notes and confirm 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 vehicle in 'Jack Mode' via the touchscreen (Service menu) before lifting to prevent the air/suspension and ride-height systems from reacting — Performance trim is coil-sprung but Jack Mode also disables certain motion alarms.
7. Loosen front wheel lug nuts while vehicle is on the ground.
8. Lift the front of the vehicle at Tesla-designated jack points using puck adapters; support with jack stands rated for EV weight.
9. Remove front wheel(s) and set aside on a soft surface to protect the finish.
10. Have a catch pan and rags ready for brake fluid; cover any painted/aluminum surfaces below the caliper.

Procedure

1. 1

   Inspect caliper variant and document
   Before disassembly, photograph the caliper from multiple angles. Identify whether the front caliper is a sliding (single/dual piston with slide pins) or fixed multi-piston design — Performance trim may use either depending on production date. This determines which torque references and rebuild kit components apply.
2. 2

   Relieve hydraulic pressure and cap reservoir
   Open the brake fluid reservoir cap briefly, then place a piece of plastic over the opening and re-cap to slow fluid migration. This reduces fluid loss when the line is disconnected.
3. 3

   Disconnect brake hydraulic line
   Using a line/flare wrench, loosen the brake line fitting at the caliper. Have a catch pan ready. Once disconnected, plug the line with a clean cap to prevent contamination and minimize drip. Note orientation of any banjo bolts and crush washers for reassembly.
   ⚠Use a flare/line wrench only — open-end wrenches will round the fitting.
   Torque spec

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

   Remove caliper from bracket / knuckle
   For a sliding caliper: remove the two caliper slide pin bolts and lift the caliper off. For a fixed caliper: remove the caliper-to-knuckle bracket bolts. Support the caliper — do not let it hang. Remove brake pads and note their orientation and any wear sensors.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)

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

   Extract piston(s)
   Place a folded shop rag in the caliper to cushion the piston. Using low-pressure compressed air at the fluid inlet (or a hydraulic piston tool), gently pop each piston out of its bore. Keep fingers clear — pistons can eject with significant force.
   ⚠️Never place fingers between the piston and caliper body — serious crush/pinch injury can occur.
6. 6

   Remove dust boots and piston seals
   Using a non-metallic seal pick, carefully remove the dust boot and the square-cut piston seal from each bore. Avoid scratching the bore — any scoring on the sealing surface will cause leaks.
7. 7

   Clean and inspect
   Clean the caliper body, bores, and pistons thoroughly with fresh brake fluid or non-residue brake cleaner. Inspect bores for pitting, scoring, or corrosion. Inspect pistons for plating damage. Replace any piston that is not smooth and uniform. Do not use mineral-oil-based solvents.
   ⚠Petroleum solvents will swell and destroy rubber seals. Use only brake-system-compatible cleaners.
8. 8

   Install new seals and pistons
   Lubricate the new piston seal with clean brake fluid or kit-supplied assembly lube and seat it in the bore groove. Install the new dust boot. Coat the piston with brake fluid and press it squarely into the bore by hand or with a piston compressor — it must go in straight without cocking. Seat the dust boot lip into the piston groove.
9. 9

   Service slide pins (if applicable)
   If the caliper is a sliding design, remove slide pins, clean them, inspect boots for tears, and re-grease with silicone brake grease before reinstallation. Replace torn boots.
10. 10

    Reinstall pads and caliper
    Reinstall brake pads with any anti-rattle clips/shims in original positions. Mount the caliper to the bracket or knuckle. Apply medium-strength threadlocker to caliper bolts as specified. Torque to OEM specification using values from the verified torque list appropriate to your caliper design.
    Torque spec

    Caliper Bolts88 Nm (65 lb-ft)

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)

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

    Reconnect brake line
    Reattach the brake line/banjo with new crush washers if applicable. Start threads by hand to avoid cross-threading. Torque to specification using a flare/line wrench.
    Torque spec

    Line Fittings20 Nm (15 lb-ft)
12. 12

    Bleed the brake system
    Top off the master cylinder with fresh DOT 4 brake fluid. Bleed the rebuilt caliper using a pressure or vacuum bleeder until clear, bubble-free fluid flows. Tesla recommends a full system bleed sequence — note that complete ABS/iBooster bleeding on Model 3 may require Tesla diagnostic software for the HCU. A manual bleed at the caliper is sufficient for the rebuilt corner; if pedal feel remains soft, dealer-level bleed is required.
    ⚠Do not let the master cylinder run dry during bleeding — air will enter the iBooster/HCU and may require Tesla service tooling to purge.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)

Reassembly

1. Reinstall the front wheel; hand-thread all lug nuts before lowering.
2. Lower the vehicle and torque lug nuts in a star pattern to specification.
3. Reconnect the 12V battery and reinstall any panels removed for access.
4. Top off the brake fluid reservoir to the MAX line with fresh DOT 4 fluid and securely cap.
5. Exit Jack Mode via the touchscreen if previously enabled.
6. Wake the vehicle and confirm no ABS, traction control, or brake warning messages appear on the instrument cluster.

Verification

• With the vehicle stationary and ignition on, pump the brake pedal — it must become firm within 2-3 strokes and hold steady under sustained pressure.
• Inspect the caliper, line fitting, and bleeder for any wetness or weeping after pressurizing the system.
• Check the touchscreen for any active brake-related alerts (ABS, brake fluid level, EBD).
• Perform a low-speed road test in a safe area: brake from 10 mph, then 25 mph, listening for any pull, grinding, or pulsation. Regen will engage strongly on the Performance trim — confirm friction brakes still engage smoothly when regen is exceeded.
• After 50–100 miles, re-inspect for leaks and re-check caliper bolt torque.
• Log this service date — Tesla recommends complete brake fluid replacement every 2 years regardless of mileage.

More procedures for this vehicle