Replace a front brake caliper on a 2024 Tesla Model S Plaid. The Plaid uses high-performance front calipers with larger rotors than standard Model S; brake fluid bleeding is required after caliper replacement.

Warnings

Tools required

Parts

• Front brake caliper assembly (Model S Plaid front, left or right specific) × 1 — OEM Tesla front caliper for Model S Plaid — verify side (LH/RH) by VIN
• Copper crush washers for banjo fitting × 2 — Match OEM size — always replace when banjo bolt is removed
• Brake pads (recommended if worn) × 1 — OEM Model S Plaid front pad set
• DOT 3 brake fluid (sealed, fresh) × 1 — Verify DOT 3 vs DOT 4 by VIN/owner's manual before use

Fluids

• DOT 3 Brake Fluid (verify by VIN — some newer Teslas spec DOT 4) — 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 16V lithium, if equipped) low-voltage battery in the frunk under the nose cowl panel. Some 2021+ Plaid units use a 16V Li-ion under the rear seat — verify location 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 the vehicle in 'Jack Mode' via the touchscreen (Controls → Service → Jack Mode) to disable air suspension self-leveling. Failure to do this can damage the air suspension or cause the vehicle to attempt to re-level on the jack.
7. Loosen front wheel lug nuts while the vehicle is on the ground.
8. Lift the vehicle ONLY at the factory-designated lift points using approved Tesla jack pads to protect the HV battery pack. Support on jack stands rated for EV weight.
9. Remove front wheel and set aside on its face to protect the finish.
10. Have a catch pan and rags ready — brake fluid will leak when the hose is disconnected.

Procedure

1. 1

   Inspect and document
   Inspect the caliper, brake hose, pads, and rotor for damage, leaks, or excessive wear. Photograph the brake hose routing and bracket clip positions for reassembly reference.
2. 2

   Clamp brake hose (optional)
   If not flushing the entire system, use a hose clamp designed for rubber brake lines to pinch the flexible portion of the hose upstream of the caliper. This minimizes fluid loss from the master cylinder reservoir. Do not clamp metal hard lines.
   ⚠Never use locking pliers or sharp-edged clamps — they will damage the hose internally.
3. 3

   Disconnect brake hose at caliper
   Place a catch pan under the caliper. Loosen and remove the banjo bolt connecting the brake hose to the caliper. Discard both copper crush washers — they must be replaced. Cap or plug the open hose to keep contamination out and minimize drip.
   ⚠Brake fluid will drip — protect the aluminum suspension components and painted surfaces.
4. 4

   Remove caliper from bracket
   Support the caliper to prevent it from dropping. Remove the two caliper-to-bracket mounting bolts. Slide the caliper off the rotor. If reusing pads, mark them for position.
5. 5

   Remove caliper bracket (if replacing as assembly)
   If the new caliper comes with a bracket or the bracket is being replaced, remove the two caliper bracket bolts from the steering knuckle. Note: these bolts use threadlocker and may require significant breakaway torque.
   ⚠Aluminum knuckle threads can strip if cross-threaded. Start bolts by hand on reinstall.
   Torque spec

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

   Transfer pads (if applicable)
   If the new caliper does not include pads and the existing pads are serviceable, transfer them and any anti-rattle hardware to the new caliper. Inspect pad backing plates and shims; replace pads if at or near minimum thickness.
7. 7

   Install new caliper bracket (if removed)
   Clean knuckle bolt holes. Apply medium-strength threadlocker to caliper bracket bolts. Install bracket and torque to specification.
   Torque spec

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

   Install new caliper
   Slide new caliper over the rotor and pads. Apply threadlocker to caliper mounting bolts (if not pre-applied) and install. Torque to specification.
9. 9

   Reconnect brake hose
   Install the brake hose to the caliper using two NEW copper crush washers — one on each side of the banjo fitting. Ensure the hose is not twisted and follows its original routing. Torque banjo bolt to specification.
   ⚠Reusing old copper washers will cause a slow leak. Always replace.
10. 10

    Bleed the brake circuit
    Top off the master cylinder reservoir with fresh DOT 3 fluid (verify spec by VIN). Bleed the corresponding front caliper at the bleeder screw using a vacuum or pressure bleeder until clean, bubble-free fluid flows. Maintain reservoir level throughout — do not let it run dry. Torque bleeder screw carefully — it is easy to overtighten and damage.
    ⚠Tesla recommends a specific bleed sequence and may require a scan tool to cycle the iBooster/ABS module for a complete bleed. Refer to the Tesla Service Manual for the correct sequence.
    ℹ️If air enters the ABS/iBooster module, a Tesla Toolbox-assisted bleed may be required — this exceeds DIY scope.
    Torque spec

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

    Final reservoir check
    Top up the master cylinder reservoir to the MAX line with fresh DOT 3 fluid. Inspect the banjo connection and bleeder for any signs of weeping.

Reassembly

1. Reinstall the front wheel. Hand-thread all lug nuts to avoid cross-threading the aluminum hub.
2. Lower the vehicle until the tire just contacts the ground, then torque lug nuts in a star pattern to specification.
3. Fully lower the vehicle and remove jack stands.
4. Reconnect the 12V/16V low-voltage battery in the frunk (or under rear seat as applicable).
5. Close frunk and allow vehicle to fully wake. Exit Jack Mode via the touchscreen — air suspension will resume normal operation.
6. With the vehicle running and in P, pump the brake pedal firmly several times until pedal is solid before attempting to drive.
7. Clean any brake fluid residue from wheel, caliper, and surrounding components with brake cleaner.

Verification

• Confirm a firm, high brake pedal — no sponginess or sink under steady foot pressure.
• Visually inspect the banjo fitting and bleeder screw for leaks after pumping the brakes.
• Check the touchscreen for any ABS, brake, or vehicle dynamics warnings. Clear any transient codes; persistent codes may indicate trapped air in the iBooster requiring a Tesla Toolbox bleed.
• Perform a low-speed test (5–10 mph) in a safe area with several gentle stops to bed in the pads and confirm even braking with no pulling.
• Gradually increase speed and braking force over the next 20–30 stops to properly bed pads against the rotor — Plaid's regenerative braking will reduce friction-brake usage, so a deliberate bed-in is important.
• Recheck reservoir level after the test drive and top up to MAX if needed.
• Re-verify torque on lug nuts after the first 50 miles.
• Note: Tesla recommends a brake fluid service every 2 years regardless of mileage — log this date if a full flush was performed.

More procedures for this vehicle