Replacement of a single front brake rotor on a 2024 Model S Long Range AWD. The Model S uses a four-piston fixed front caliper on Long Range trims; this procedure covers caliper removal, rotor swap, and torque-critical reassembly.

Warnings

Tools required

Parts

• Front brake rotor (OEM or OE-equivalent for 2024 Model S Long Range, verify size by trim — 19"/21" wheel package affects rotor spec) × 1 — Manufacturer-specified front rotor for 2024 Model S LR AWD
• Rotor retaining set screw (replacement recommended if corroded) × 1 — OEM set screw

Preparation

1. Park on level ground, place in P, engage parking brake via the touchscreen.
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 (or 16V Li-ion on Plaid-equipped variants) low-voltage battery under the nose cowl panel. Verify by attempting to wake the car — it should not respond.
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. Disable Sentry Mode and Cabin Camera prior to entering Service Mode-equivalent state if available; do not enter Service Mode without proper training.
7. Loosen the front wheel lug nuts (do not remove) while the wheel is on the ground.
8. Lift the vehicle at the manufacturer-specified front jack point using a Tesla puck adapter. Support with jack stands rated for the vehicle weight.
9. Verify the opposite wheels are chocked.

Procedure

1. 1

   Remove front wheel
   Fully remove the lug nuts and pull the front wheel off. Set the wheel face-down on a soft surface to protect the finish.
   ⚠Model S wheels (especially 21" Arachnid-style) are easily curbed/scratched — handle with care.
2. 2

   Inspect caliper and surrounding area
   Inspect the caliper, brake hose, and dust shield for damage. Verify there are no orange HV cables routed nearby (there should not be on a front corner — front motor HV runs internally to the drive unit). Note pad thickness; if pads are below 3 mm, replace them with the rotor.
3. 3

   Support caliper and remove caliper from bracket (or bracket from knuckle)
   Model S Long Range front calipers are typically a fixed multi-piston design bolted directly to the steering knuckle (no separate sliding bracket on some configurations). Remove the two caliper-to-knuckle mounting bolts. If your specific configuration has a sliding caliper with a bracket and slide pins, remove the slide pin bolts instead and lift the caliper off the bracket. Support the caliper with a hanger — DO NOT let it hang by the brake hose.
   ⚠Do not press the brake pedal while the caliper is removed — pistons can pop out.
   Torque spec

   Caliper Bracket Bolts102 Nm (75 lb-ft)

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
4. 4

   Remove caliper bracket if applicable
   If a separate caliper bracket is present, remove the two caliper bracket bolts from the steering knuckle and set the bracket aside. On fixed-caliper configurations, this step is already complete.
   Torque spec

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

   Remove rotor set screw and rotor
   Remove the small Torx/hex set screw retaining the rotor to the hub. If the rotor is corroded to the hub, thread two bolts into the threaded extraction holes (if present) and tighten alternately to push the rotor off, OR strike the rotor hat (NOT the hub or knuckle) with a dead-blow mallet. Do not strike aluminum suspension components.
   ⚠Aluminum knuckle/hub components — never use a steel hammer directly on suspension parts.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
6. 6

   Clean hub face
   Wire-brush the hub face thoroughly to remove rust and debris. A clean, flat hub face is critical to prevent rotor runout. Wipe with brake cleaner. A very thin film of anti-seize on the hub center (NOT the wheel mounting face) helps prevent future seizure.
7. 7

   Install new rotor
   Remove protective coating from the new rotor with brake cleaner on both friction surfaces. Mount the rotor over the hub and install the set screw. Confirm the rotor seats flush against the hub.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
8. 8

   Reinstall caliper bracket (if separate)
   If a separate bracket was removed, apply medium-strength threadlocker to the bracket bolt threads and install. Torque to specification. Verify sequence per the Tesla Service Manual if both bolts are torque-critical in a specific order.
   Torque spec

   Caliper Bracket Bolts102 Nm (75 lb-ft)
9. 9

   Reinstall caliper
   If a fixed caliper was removed from the knuckle, reinstall using the caliper bracket bolt torque (front). If a sliding caliper, apply silicone brake grease to slide pins, reinstall caliper over pads/rotor, and torque slide pin bolts. Confirm the brake hose is not twisted or kinked.
   Torque spec

   Caliper Bolts88 Nm (65 lb-ft)

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Pump brake pedal
    With the 12V still disconnected, pump the brake pedal 5–10 times until firm. This re-seats the pads against the new rotor. Do not drive until the pedal is firm.
11. 11

    Reinstall wheel
    Mount the wheel and hand-thread all lug nuts. Lower the vehicle until the tire just contacts the ground, then torque the lug nuts in a star pattern to specification.
    ⚠Verify lug nut torque after 50 miles — Tesla wheels with aftermarket spacers or anti-seize on studs require special attention.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Lower the vehicle fully to the ground.
2. Reconnect the 12V (or 16V) low-voltage battery in the frunk.
3. Close the frunk and wake the vehicle with the key fob.
4. Check the touchscreen for any brake system or ABS faults.
5. Top off brake fluid reservoir if needed using DOT 3 (or DOT 4 if specified for this VIN — verify before adding).
6. Re-enable Sentry Mode and any features disabled during prep.

Verification

• With the vehicle stationary and the brake pedal pressed, confirm a firm, high pedal — no sponginess.
• Drive slowly in a safe area and perform low-speed stops to confirm normal braking with no pulling, grinding, or vibration.
• Perform a brake bed-in procedure: 6–10 moderate stops from ~35 mph down to ~5 mph without coming to a complete stop, then drive several minutes to cool. Because Model S regen handles most deceleration, you may want to temporarily set regen to 'Low' (if available on this firmware) or use the Hold/Creep mode that minimizes regen during bed-in.
• After the first 50 miles, re-torque the wheel lug nuts to the wheel lug nut specification.
• Confirm no ABS, traction control, or brake warning indicators appear on the touchscreen.
• Reminder: Tesla recommends brake fluid replacement every 2 years regardless of mileage — log this service date and plan accordingly.

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