Replace a rear brake hose on a 2024 Model S Plaid. The rear caliper uses a banjo-fitting hose to a hard-line bracket on the subframe; the system must be bled afterward and brake fluid must meet the spec on the reservoir cap (DOT 3 per database, but verify by VIN).

Warnings

Tools required

Parts

• Rear brake hose assembly (left or right as applicable) × 1 — OEM Tesla Model S 2024 rear brake hose — order by VIN
• Copper sealing washers for banjo fitting × 2 — Match OEM banjo bolt size — typically two per banjo
• Brake hose retaining clip (frame-side) × 1 — OEM-style horseshoe/U-clip — replace if deformed

Fluids

• DOT 3 Brake Fluid (verify spec on reservoir cap by VIN — some newer S/X require 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 low-voltage battery. On 2024 Model S Plaid this is typically a 16V lithium unit located under the rear seat — remove the seat cushion and disconnect the negative terminal. Confirm location for your specific build before cutting power.
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 (Service menu) before lifting to disable air suspension self-leveling on this Plaid trim.
7. Loosen the rear wheel lug nuts while the vehicle is still on the ground.
8. Lift the rear of the vehicle at the manufacturer-specified rear lift points using approved pucks; support on jack stands rated for EV weight.
9. Remove the rear wheel on the side being serviced.
10. Open the brake fluid reservoir cap, then re-seat it loosely (or seal with plastic wrap under the cap) to slow fluid loss without pulling air through the master/iBooster.
11. Place a catch pan under the rear caliper area.

Procedure

1. 1

   Inspect and photograph the hose routing
   Before disturbing anything, photograph the brake hose routing from caliper to body-side hard line. Note the orientation of the banjo fitting at the caliper, the position of the frame-side bracket clip, and any anti-rotation tab orientation. The replacement hose must be installed without twist.
2. 2

   Pinch off the hose (optional)
   If using a brake-rated rubber-jaw pinch-off clamp, clamp the flexible section of the old hose to minimize fluid loss from the reservoir. Do not use locking pliers or sharp-jaw clamps — these damage the hose's inner liner and are unsafe even on a hose being removed (debris can flow upstream).
   ⚠Skip pinching if the hose shows any external damage; pinching a damaged hose can dislodge debris into the ABS module.
3. 3

   Disconnect the hard line from the hose at the body-side fitting
   Using a flare-nut (line) wrench, hold the hex on the brake hose end fitting with a backup wrench and loosen the hard-line tube nut. Catch fluid in the pan. Once cracked loose, fully separate the hard line and cap it with a clean plug or vinyl cap to keep contaminants out.
   ⚠Do not twist the hard line — kinking the steel line will require replacement of that section.
   Torque spec

   Line Fittings20 Nm (15 lb-ft)
4. 4

   Release the hose from the frame-side bracket
   Remove the horseshoe/U-clip securing the hose end fitting to the body-side bracket. Pull straight to avoid bending the bracket. Inspect the clip; replace if distorted.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
5. 5

   Disconnect any intermediate hose retainer
   If the rear hose is secured by an intermediate clip or P-clamp to the suspension upright or subframe arm, remove the retaining bolt. Note its location for reinstallation.
6. 6

   Remove the banjo bolt at the caliper
   Place the catch pan directly under the caliper banjo. Using the correct hex socket, unscrew the banjo bolt from the rear caliper inlet. Discard both copper sealing washers — they are single-use. Allow residual fluid to drain into the pan, then plug the caliper port with a clean lint-free rag.
   ⚠Do not reuse the old copper washers. Reused washers will weep brake fluid under pressure.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
7. 7

   Remove the old hose
   Withdraw the old hose from the vehicle. Compare side-by-side with the new hose: length, end fitting orientations, banjo bolt clearance hole size, and any anti-rotation tab must match. Do not install if the part is incorrect.
8. 8

   Install the new hose at the caliper
   Place a NEW copper washer on each side of the banjo eyelet (one between bolt head and eyelet, one between eyelet and caliper). Confirm any anti-rotation tab on the banjo seats into its locating hole on the caliper. Thread the banjo bolt by hand, then torque.
   ⚠Do not over-torque the banjo bolt — the hollow bolt can crack and fail under braking pressure.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
9. 9

   Route the hose and seat into body-side bracket
   Route the new hose along the original path with no twist or contact with suspension/exhaust. Seat the upper end fitting into the body-side bracket and install the retaining U-clip fully. The fitting should not rotate or pull out by hand.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
10. 10

    Reconnect the hard line
    Start the hard-line tube nut by hand into the hose fitting to avoid cross-threading. Use a flare-nut wrench on the tube nut and a backup wrench on the hose hex; tighten to specification.
    Torque spec

    Line Fittings20 Nm (15 lb-ft)
11. 11

    Reinstall any intermediate retainer
    Reinstall the intermediate P-clamp/retainer if equipped. Torque to OEM specification — refer to Tesla Service Manual.
12. 12

    Cycle the suspension and check for interference
    With the wheel still off, slowly cycle the rear suspension by hand (or have an assistant raise/lower the corner) and verify the new hose does not contact the tire, upright, or sway bar at any point of travel. The hose must not twist as the suspension moves.
13. 13

    Bleed the rear caliper
    Top up the brake fluid reservoir with the correct DOT spec for this VIN. Attach a clear bleed hose to the caliper bleeder screw, submerge the end in fresh fluid in a catch bottle, and bleed the caliper using your preferred method (vacuum, pressure, or two-person pedal) until clean, bubble-free fluid flows. Keep the reservoir topped up — never let it run dry. Torque the bleeder screw.
    ⚠Do not use Toolbox-required service-mode bleed procedures (ABS auto-bleed) without the software. A standard caliper bleed is sufficient when only the caliper-side hose was opened and air was not introduced upstream.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
14. 14

    Set fluid level and seal reservoir
    Set brake fluid to the MAX line on the reservoir. Wipe down any spilled fluid with brake parts cleaner — do NOT let fluid sit on aluminum body panels or paint. Securely close the reservoir cap.

Reassembly

1. Reinstall the rear wheel; snug lug nuts by hand.
2. Lower the vehicle to the ground.
3. Final-torque the wheel lug nuts in a star pattern.
4. Reconnect the low-voltage (12V/16V) battery negative terminal and reinstall any covers/seat cushions removed for access.
5. Close the frunk/seat and ensure the doors recognize the key fob normally.

Verification

• With the vehicle off and key fob present, press the brake pedal firmly several times. The pedal should be firm with no sponginess and no progressive sink under sustained pressure.
• Inspect the new hose at both ends (banjo at caliper, hard-line at bracket) with a flashlight after pedal pressure — there must be zero weeping or seepage.
• Power on the vehicle and clear any 'Vehicle was serviced' or low-voltage reset notifications. Confirm no ABS, traction control, or 'Brake system needs service' alerts on the touchscreen.
• Drive at low speed in a safe area and perform several gradual stops, then a firmer stop. Pedal feel should match the front-only or opposite-side feel; pulling, low pedal, or warning lights mean air remains in the system.
• Re-inspect the hose connections after the test drive while the system is still pressurized from use.
• Reminder: Tesla recommends a full brake fluid flush every 2 years — log this service date and consider a complete flush at the next interval if not done now.
• Note: Drive unit fluid (rear gear oil, 75W-90 GL-5) is no longer 'lifetime' per Tesla's updated guidance — inspect at 12,500 mi initial, then every 25,000–50,000 mi.

More procedures for this vehicle