Replacement of a front brake caliper on a 2024 Tesla Model S Long Range AWD. This job involves opening the hydraulic system, so brake fluid bleeding is required afterward.

Warnings

Tools required

Parts

• Front brake caliper assembly (left or right as applicable) × 1 — Tesla OEM front caliper for 2024 Model S Long Range — verify by VIN
• Copper crush washers for banjo bolt × 2 — Match OEM banjo bolt size — always replace
• Brake pads (recommended if old pads are worn or contaminated) × 1 — Tesla OEM front pads for Model S 2024

Fluids

• DOT 3 Brake Fluid (verify spec on reservoir cap by VIN — some newer Model S use DOT 4) — 1 qt

Preparation

1. Park on level ground, place in P, engage the parking brake.
2. Exit ALL doors with the key fob/phone key away from the vehicle. Wait at least 2 minutes for HV systems to fully de-energize, even on this non-HV job.
3. Open the frunk and disconnect the 12V low-voltage battery (located under the front trunk nose cowl panel on 2024 Model S). Follow the on-screen 'Power Off' option in Service Mode if available before disconnect.
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. Loosen the front wheel lug nuts a half-turn while the vehicle is on the ground.
7. Lift the front of the vehicle at the manufacturer-specified jack points using rubber pucks, and support on jack stands rated for the vehicle weight.
8. Remove the front wheel and set aside on its face to protect the finish.
9. Place a drip pan beneath the caliper to catch brake fluid.
10. Open the brake fluid reservoir cap in the frunk to reduce hydraulic pressure, but cover the opening with a lint-free rag to keep contaminants out.

Procedure

1. 1

   Inspect and document
   Photograph the caliper, brake hose routing, and any wear indicator/sensor wiring before disassembly. Confirm you have the correct side (left vs right) replacement caliper and that bleeder screws are oriented upward when installed.
2. 2

   Disconnect brake pad wear sensor (if equipped)
   If the front pads have an electronic wear sensor connector, release the locking tab and unplug it. Free the harness from any clips on the caliper or knuckle.
3. 3

   Disconnect the brake hose at the caliper
   Place a catch pan under the caliper. Loosen the banjo bolt at the caliper inlet and remove it along with the two copper crush washers. Immediately cap or plug the brake hose to minimize fluid loss and contamination. Discard the old copper washers — they must be replaced.
   ⚠Brake fluid will drip. Protect aluminum bodywork and painted surfaces.
4. 4

   Remove the caliper from the bracket
   Remove the two caliper guide/mounting bolts that secure the caliper body to the caliper bracket. Slide the caliper off the rotor. If retaining the existing pads, set them aside in order. If reusing the bracket, leave it bolted to the knuckle.
5. 5

   (Optional) Remove the caliper bracket
   If the new caliper assembly comes with a bracket, or if the bracket is being replaced, remove the two caliper bracket bolts that secure the bracket to the steering knuckle. These are high-torque fasteners — expect significant breakaway force. Clean threads in the knuckle thoroughly.
   ⚠Aluminum knuckle — do not damage threads. If the bolts feel galled, stop and consult the service manual.
   Torque spec

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

   Transfer pads (if reusing) and prepare new caliper
   Inspect the new caliper for shipping plugs and remove them. Verify the bleeder screw is at the top when oriented for installation. If transferring pads, install them and any anti-rattle clips into the bracket per OEM orientation.
7. 7

   Install caliper bracket (if removed)
   Apply medium-strength threadlocker to the caliper bracket bolt threads. Install the bracket onto the knuckle and torque the bolts to specification.
   Torque spec

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

   Install the new caliper
   Slide the new caliper over the rotor and pads onto the bracket. Install the caliper guide/mounting bolts and torque to specification. Verify the caliper moves freely on its slides (if a floating design) and that pads are seated correctly.
9. 9

   Reconnect the brake hose
   Install the brake hose to the new caliper using TWO NEW copper crush washers (one on each side of the banjo fitting). Hand-start the banjo bolt to avoid cross-threading the aluminum caliper, then torque to the banjo bolt specification.
   ⚠Reusing copper washers will cause a brake fluid leak. Always replace.
10. 10

    Bleed the brake circuit
    Top off the master cylinder reservoir with the manufacturer-specified DOT brake fluid (verify DOT 3 vs DOT 4 by reservoir cap labeling on this 2024 vehicle). Bleed the affected front caliper using a vacuum or pressure bleeder until clear, bubble-free fluid flows. Tesla Model S typically requires a scan-tool-assisted bleed for the iBooster/ABS module to fully purge the system; a manual bleed at the caliper is sufficient for the caliper-only circuit, but if the pedal is soft, an iBooster bleed via Tesla service software will be required. Torque the bleeder screw to specification — do not overtighten.
    ⚠Never let the master cylinder reservoir run dry during bleeding — air ingestion into the iBooster will require a Tesla-certified bleed procedure.
    Torque spec

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

    Reconnect wear sensor and reinstall wheel
    Reconnect the pad wear sensor connector if equipped. Reinstall the wheel, hand-tighten the lug nuts in a star pattern, then lower the vehicle to the ground.
12. 12

    Final torque on lug nuts
    With the wheel on the ground, torque the lug nuts in a star pattern to specification. Do not use an impact wrench for final torque.

Reassembly

1. Verify brake fluid level is at the MAX line on the reservoir; cap the reservoir.
2. Reconnect the 12V battery in the frunk; reinstall the nose cowl panel.
3. Close the frunk and allow the vehicle to fully wake up (touchscreen boot, instrument cluster initialization).
4. Clear any transient warnings on the touchscreen — note that some ABS/stability warnings may persist until the vehicle is driven a short distance at low speed.
5. Clean any brake fluid residue from the caliper, suspension, and bodywork with water and a clean rag.

Verification

• With the vehicle stationary and ignition on, pump the brake pedal several times. The pedal should become firm and hold steady pressure without sinking — a sinking pedal indicates air or a leak.
• Inspect the banjo fitting and bleeder screw for any seepage after pedal pressure is applied.
• Confirm the touchscreen shows no ABS, traction control, or brake system warnings.
• Drive the vehicle at low speed (5–10 mph) in a safe area and apply the brakes gently several times to verify normal stopping behavior. Then test at progressively higher speeds.
• After the first drive, re-inspect the caliper banjo fitting for leaks and check the brake fluid reservoir level.
• Reminder: Tesla recommends brake fluid service every 2 years regardless of mileage. Log this service date so the next interval can be scheduled.
• If the pedal remains soft or the touchscreen reports an ABS/iBooster fault, a Tesla service tool bleed of the brake booster/ABS module is required — do not drive the vehicle in this condition.

More procedures for this vehicle