Replacement of a rear brake caliper on a 2024 Tesla Model S Plaid. The Plaid uses high-performance rear calipers with larger rotors than the standard Model S — verify the replacement caliper matches the Plaid-specific part before installation.

Warnings

Tools required

Parts

• Rear brake caliper assembly (Model S Plaid-specific) × 1 — OEM Tesla Model S Plaid rear caliper — verify left/right and Plaid fitment by VIN
• Copper crush washers for banjo fitting × 2 — Match OEM banjo bolt size — always replace, never reuse
• Brake pads (recommended if worn) × 1 — OEM-spec rear pads for Model S Plaid

Fluids

• DOT 3 Brake Fluid (verify DOT 3 vs DOT 4 by VIN — newer Plaids may specify 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, located under the rear seat on 2021+ Plaid) low-voltage battery. Refer to the owner's manual for the exact disconnect procedure on your VIN.
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. Before disconnecting 12V/16V power, enter the touchscreen Service menu and place the Electronic Parking Brake (EPB) into 'Brake Service Mode' (or equivalent transport/caliper service mode). This retracts the EPB actuator and allows manual piston compression.
7. Loosen the rear wheel lug nuts a half turn while the vehicle is still on the ground.
8. Raise the rear of the vehicle using only the manufacturer-specified lift points and Tesla-approved jack pucks. Support on jack stands rated for EV weight.
9. Remove the rear wheel and set the lug nuts aside in a clean location.

Procedure

1. 1

   Inspect and document
   Photograph the caliper, brake hose routing, EPB connector routing, and any cable clips before disassembly. Note pad thickness and rotor condition. On Plaid, the rear rotors are larger than standard Model S — confirm replacement caliper fitment.
2. 2

   Disconnect the EPB electrical connector
   Locate the electronic parking brake actuator connector at the rear of the caliper. Release the locking tab and disconnect. Tuck the harness aside so it is not strained when the caliper is removed.
   ⚠Confirm EPB is in service mode before disconnecting. A live EPB harness disconnected without service mode can set faults that require Tesla Toolbox to clear.
3. 3

   Prepare the hydraulic line
   Place a catch pan under the caliper. Loosen the brake hose banjo bolt one-quarter turn while the caliper is still mounted to break it loose, but do not remove yet. This minimizes spilled fluid and prevents stripping the fitting under load.
4. 4

   Remove the caliper guide/slide bolts
   Remove the two caliper bolts that secure the caliper body to the bracket. Support the caliper as the second bolt is removed. If only the caliper body is being replaced (not the bracket), leave the bracket attached to the knuckle.
5. 5

   Remove the caliper bracket (if replacing complete assembly)
   If the full caliper bracket assembly is being replaced, remove the two bracket-to-knuckle bolts. These are torque-to-spec critical fasteners holding the caliper to the rear suspension knuckle.
   ⚠Bracket bolts are very high torque (100 Nm) and may be installed with thread locker — use a long breaker bar and proper-fit socket to avoid rounding.
   Torque spec

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

   Disconnect the brake hose
   Position the catch pan, then remove the banjo bolt completely. Capture the two copper crush washers (one on each side of the banjo fitting) and discard. Cap the open hose end immediately to prevent contamination and minimize fluid loss. Remove the caliper from the vehicle.
   ⚠Never reuse copper crush washers — they will leak. New washers are mandatory.
7. 7

   Transfer pads (if reusing)
   If the existing pads are within service spec and being reused, transfer them to the new caliper following the manufacturer-specified pad retention hardware orientation. Otherwise, install new pads now.
   ℹ️Pad replacement is a strong recommendation any time a caliper is replaced, especially on Plaid where regenerative braking can cause uneven pad wear.
8. 8

   Install the new caliper / bracket
   If the bracket was removed, install it onto the knuckle with the bracket bolts. Apply medium-strength thread locker as specified. Torque to specification. Then mount the caliper body to the bracket using the caliper bolts with thread locker, and torque to specification.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
9. 9

   Reconnect the brake hose
   Install the banjo fitting with NEW copper crush washers — one on each side of the banjo eyelet. Hand-thread the banjo bolt to avoid cross-threading, then torque to specification. Verify the hose is not twisted and routes cleanly without contacting the suspension or wheel.
10. 10

    Reconnect the EPB connector
    Reconnect the electronic parking brake harness to the caliper actuator. Verify the locking tab is fully seated and the harness is routed in its original clips, away from the rotor and any moving suspension components.
11. 11

    Bleed the brake circuit
    Top off the master cylinder reservoir with the correct DOT-spec brake fluid (verify DOT 3 vs DOT 4 by VIN). Bleed the rear caliper at the bleeder screw using a pressure or vacuum bleeder until clean, bubble-free fluid flows. Torque the bleeder screw to specification — do not overtighten, as this is a soft brass fitting.
    ⚠Do not allow the master cylinder reservoir to run dry during bleeding — air in the ABS/iBooster module on Tesla vehicles typically requires Tesla Toolbox to fully purge.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
12. 12

    Reinstall the 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 to specification in a star pattern.

Reassembly

1. Reconnect the 12V/16V low-voltage battery.
2. Power on the vehicle (do not drive yet). Allow systems to fully boot.
3. Exit Brake Service Mode via the touchscreen Service menu — this re-engages and calibrates the EPB actuator. Listen for the EPB to cycle.
4. With the vehicle in P and parking brake engaged, pump the brake pedal firmly 5-10 times until pedal feel is firm and consistent. Top off brake fluid reservoir to the MAX line.
5. Inspect the banjo fitting and bleeder screw for any sign of weeping fluid.
6. Cycle the EPB on/off several times via the touchscreen and confirm no fault messages appear on the instrument cluster.

Verification

• With the vehicle stationary, confirm no ABS, brake, or EPB fault messages on the touchscreen. If any appear, a scan tool (Tesla Toolbox or compatible) may be required to clear codes after bleeding.
• Perform a low-speed brake test in a safe area (5-10 mph) before any highway driving — confirm pedal is firm, no pulling to one side, and no grinding.
• Test the EPB: with the vehicle stopped, engage and disengage the parking brake via the touchscreen and confirm normal operation with no unusual noise.
• After 10-20 miles of varied driving, re-inspect the banjo fitting, bleeder screw, and caliper bolts for leaks or loosening. Top off brake fluid reservoir as needed.
• Tesla recommends a complete brake fluid flush every 2 years regardless of mileage — log this service date so the next flush can be scheduled.
• Note: Plaid's regenerative braking does most of the deceleration work, so bed-in the new pads/caliper with several moderate friction stops from 40-10 mph to ensure proper pad-to-rotor mating.

More procedures for this vehicle