Replacement of a rear brake caliper on a 2024 Model S Long Range AWD. The rear calipers are integrated with the electric parking brake (EPB) actuator, so the EPB must be placed in service/transport mode via the touchscreen before disconnecting the actuator harness.

Warnings

Tools required

Parts

• Rear brake caliper assembly (with integrated EPB actuator) × 1 — OEM Tesla Model S 2024 rear caliper — match left/right side
• Copper sealing washers for banjo bolt × 2 — Match caliper banjo size
• Brake pad set (recommended if pads are worn or contaminated) × 1 — OEM rear pad set
• Caliper bracket bolts (if not reusable) × 2 — OEM specification

Fluids

• DOT 3 Brake Fluid (verify VIN — newer Model S may specify 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. Before disconnecting 12V: in the touchscreen, navigate to Service Mode and place the EPB into 'Brake Service Mode' (or equivalent) to retract and disable the rear caliper actuators. Confirm the EPB indicator state.
4. Disconnect the 12V low-voltage battery in the frunk under the nose cowl panel (or 16V Li-ion under rear seat on applicable Plaid units — verify per architecture notes).
5. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal.
6. 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.
7. Loosen rear wheel lug nuts while the vehicle is on the ground.
8. Raise the rear of the vehicle using Tesla-specified jack/lift points and support on rated jack stands. Confirm stability before working under the vehicle.
9. Remove the rear wheel.
10. Inspect the brake fluid reservoir level and remove some fluid if full to prevent overflow when pistons are compressed.

Procedure

1. 1

   Disconnect EPB actuator connector
   Locate the electric parking brake harness connector on the rear caliper. Release the locking tab and unplug the connector. Do not pull on the wires. Secure the harness aside so it is not damaged during caliper removal.
   ⚠Verify EPB service mode was successfully engaged before unplugging. If the actuator is still applied, the new caliper cannot be installed without Tesla software intervention.
2. 2

   Clamp the flexible brake hose
   Using a proper rubber-jaw brake hose clamp, gently pinch the flexible rubber portion of the rear brake hose upstream of the caliper to minimize fluid loss. Do not clamp on a hard line or on a fitting.
3. 3

   Disconnect the brake hose at the caliper
   Place a catch pan beneath the caliper. Remove the banjo bolt securing the brake hose to the caliper inlet. Discard the two copper sealing washers — they must be replaced. Cap or plug the open hose end immediately to prevent contamination and fluid loss.
   ⚠Brake fluid will damage paint. Wipe immediately and flush with water.
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 and brake pads. Inspect pads, rotor, and bracket for wear or damage.
5. 5

   Remove caliper bracket (if replacing as assembly or required by procedure)
   If the replacement caliper is supplied with a new bracket or the bracket must be removed for access, remove the two caliper bracket-to-knuckle bolts. Note original orientation. Clean the mating surfaces of corrosion before reinstallation.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
6. 6

   Transfer pads and prepare the new caliper
   Transfer the brake pads to the new caliper/bracket if pads are within service spec, otherwise install new pads. Verify the caliper piston is fully retracted (it should be, since EPB service mode was engaged on the old unit and the new unit ships retracted). Apply a thin film of manufacturer-approved brake caliper grease to slide pin contact areas only — keep grease off pad friction surfaces and rotor.
   ⚠Do not attempt to manually wind back a rear EPB-integrated piston without the proper tool and procedure — internal damage to the actuator can result.
7. 7

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

   Caliper Bracket Bolts100 Nm (74 lb-ft)
8. 8

   Install the new caliper
   Position the new caliper over the pads and rotor. Install the caliper mounting bolts and torque to specification.
9. 9

   Reconnect brake hose with new copper washers
   Install the brake hose to the caliper using TWO NEW copper sealing washers (one on each side of the banjo fitting). Torque the banjo bolt to specification. Verify hose orientation is not twisted and clears suspension throughout travel.
   ⚠Reusing copper washers will cause leaks. Always replace.
10. 10

    Reconnect EPB actuator harness
    Plug the EPB connector into the new caliper until it locks. Verify connector is fully seated and the locking tab is engaged. Route the harness in its original path and secure any clips.
11. 11

    Remove hose clamp and bleed the caliper
    Remove the brake hose clamp. Top up the brake fluid reservoir with fresh, sealed DOT-spec fluid (verify DOT 3 vs DOT 4 by VIN). Bleed the rear caliper at the bleeder screw using a pressure bleeder or two-person method until clean, bubble-free fluid flows. Maintain reservoir level throughout. Torque the bleeder screw to specification — do not overtighten.
    ⚠Verify Tesla service manual bleed sequence by VIN — Model S bleed order may differ from generic four-corner sequences.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)

Reassembly

1. Top off brake fluid reservoir to MAX line with correct DOT-spec fluid and seal the cap.
2. Reinstall the rear wheel; snug lugs in a star pattern.
3. Lower vehicle to the ground.
4. Final-torque the wheel lug nuts in a star pattern.
5. Reconnect the 12V (or 16V) low-voltage battery.
6. Allow the vehicle to wake and complete its boot sequence; sit in the driver's seat with the brake pedal depressed to bring systems online.
7. Exit Brake Service Mode via the touchscreen and command the EPB to apply/release several times to verify the new actuator functions and self-calibrates.

Verification

• With vehicle stationary and wheels chocked, press the brake pedal firmly several times — pedal should become firm and not sink. A soft or sinking pedal indicates air in the system or a leak.
• Apply and release the EPB from the touchscreen multiple times. Listen for the actuator running and verify no fault messages appear on the instrument cluster.
• Inspect the banjo fitting and bleeder screw for any wetness or seepage after pedal pressure tests.
• Confirm no ABS, EPB, or brake warning indicators are displayed. If any DTCs persist, Tesla diagnostic software may be required to clear codes or perform EPB calibration.
• Perform a low-speed road test in a safe area: verify straight braking with no pull, no abnormal noise, and that EPB engages/releases normally. Bed in the pads if new pads were installed, per pad manufacturer's bedding procedure.
• Recheck reservoir level after road test. Tesla recommends brake fluid replacement every 2 years — log this service date for the next interval.

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