Replacement of a single front brake rotor on a 2024 Model S Plaid. The Plaid uses large performance front brakes (typically 4-piston fixed or floating calipers depending on build), so caliper weight and rotor size require care during handling.

Warnings

Tools required

Parts

• Front brake rotor (Model S Plaid front-specific) × 1 — OEM Tesla front rotor for 2024 Model S Plaid — verify by VIN
• Rotor set screw × 1 — OEM set screw — replace if damaged on removal
• Brake pads (recommended to replace as a pair if worn) × 1 — OEM Tesla front pad set — optional with rotor service

Fluids

• DOT 3 Brake Fluid (verify DOT 3 vs DOT 4 by VIN before topping off)

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 under rear seat) low-voltage battery in the frunk under the nose cowl panel. Verify which battery system this VIN uses 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 BEFORE disconnecting 12V power (Service > Jack Mode) to prevent air suspension from auto-leveling and to disable load-leveling on Plaid air-equipped trims.
7. Loosen the front wheel lug nuts ~1/4 turn while the wheel is still on the ground.
8. Lift the front of the vehicle using ONLY Tesla-approved jack pad pucks at the factory lift points. Support on rated jack stands.
9. Remove the front wheel on the side being serviced.
10. Inspect the brake hose, ABS sensor wiring, and pad wear sensor (if equipped) before disassembly. Note routing for reinstallation.

Procedure

1. 1

   Inspect brake assembly
   Visually inspect the caliper, pads, rotor, brake hose, and ABS sensor wiring. Note any cracked dust boots, leaking pistons, or damaged hardware. The Plaid uses a performance front caliper — confirm caliper bolt type (slide pin vs. fixed bracket bolts) before proceeding, as procedure differs.
2. 2

   Retract caliper pistons (if reusing pads)
   If pads will be reused, gently retract the pistons using a piston compressor tool to create clearance. Open the brake fluid reservoir cap in the frunk before retracting to relieve pressure, and monitor reservoir level — do not overflow. Do not force pistons; if they will not retract, inspect for seized hardware.
   ⚠Tesla regen-heavy driving can leave pistons partially extended and stiff. Force on a stuck piston can damage the seal.
3. 3

   Remove caliper from bracket (if floating-style) or remove caliper assembly
   For a floating caliper: remove the two caliper slide pin bolts and lift the caliper off the bracket. For a fixed multi-piston caliper (common on Plaid front), remove the two caliper bracket bolts that attach the caliper assembly to the knuckle. Support the caliper with a hanger — do NOT let it dangle from the brake hose.
   ⚠Plaid front calipers are notably heavier than typical Model S calipers. Have a hanger ready before the last bolt comes out.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)

   Bracket Bolts102 Nm (75 lb-ft)
4. 4

   Remove caliper bracket (if applicable)
   If a separate caliper carrier bracket is used and it remains on the knuckle, remove it now using the bracket bolts. On fixed-caliper Plaid setups, this step may not apply if the caliper bolts directly to the knuckle.
   Torque spec

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

   Remove rotor set screw
   Remove the small rotor retaining set screw from the rotor face. These screws can seize — use a properly fitting bit and impact driver if needed to avoid stripping. Replace the screw if damaged.
   Torque spec

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

   Remove rotor
   Pull the rotor straight off the hub. If the rotor is stuck due to corrosion at the hub face, thread two bolts into the threaded jacking holes (if present) and tighten evenly to push the rotor off. Do NOT strike the rotor face or hub with a steel hammer — use a dead-blow on the rotor hat only if necessary.
   ⚠Aluminum knuckle and hub components — impact damage is expensive and can affect bearing alignment.
7. 7

   Clean hub face
   Wire-brush the hub mating face to remove all rust and debris. The new rotor must seat flat against a clean hub or you will induce runout and pulsation. Apply a very thin film of anti-seize to the hub center only (not the mating face that contacts the rotor). Wipe new rotor with brake cleaner to remove shipping oil.
8. 8

   Install new rotor
   Slide the new rotor onto the hub, aligning the set screw hole with the threaded hole in the hub. Install the rotor set screw and torque to specification.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
9. 9

   Reinstall caliper bracket (if removed)
   Reinstall the caliper bracket to the knuckle. Apply medium-strength threadlocker to the bracket bolts and torque to specification.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
10. 10

    Reinstall caliper / pads
    Reinstall pads (new or original) into the bracket or caliper. Reinstall the caliper over the rotor. For slide-pin designs, apply silicone brake grease to the slide pins and torque the slide pin bolts. For fixed calipers, apply threadlocker to caliper-to-knuckle bolts and torque to specification.
    ⚠Verify pad clips and anti-rattle hardware are seated correctly before tightening — Plaid brakes will squeal aggressively if pads are misaligned.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)

    Caliper Bolts88 Nm (65 lb-ft)
11. 11

    Verify brake fluid level
    Check the brake fluid reservoir in the frunk. Top up with the correct DOT specification (verify DOT 3 vs DOT 4 by VIN — this 2024 Plaid likely calls for the newer spec; consult the reservoir cap and Tesla service manual). If pedal feel is questionable after reassembly, the system should be bled per OEM sequence.
    ℹ️Tesla recommends brake fluid replacement every 2 years regardless of mileage. Note this service date.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)

Reassembly

1. Reinstall the front wheel. Hand-thread all lug nuts before applying any torque.
2. Lower the vehicle until the tire just contacts the ground, then torque lug nuts in a star pattern to specification.
3. Lower the vehicle fully and remove jack stands.
4. Reconnect the 12V/16V low-voltage battery in the frunk. Reinstall cowl/nose panel.
5. Exit Jack Mode via the touchscreen once the vehicle is powered back on.
6. With the vehicle in P and parking brake set, pump the brake pedal firmly several times until pedal becomes firm — this seats the pads against the new rotor and restores piston position. Do NOT attempt to drive until pedal is firm.

Verification

• Confirm firm brake pedal before moving the vehicle. A soft or sinking pedal indicates air in the system or a hydraulic issue — do not drive.
• Check the touchscreen for any brake system, ABS, or stability control alerts after powering up. Plaid's brake-by-wire-assist systems may flag a fault if a sensor was disturbed.
• Perform a low-speed brake test in a safe area (5–10 mph stops) before normal driving.
• Bed in the new rotor per the rotor manufacturer's procedure — typically a series of moderate stops from ~40 mph to ~10 mph, avoiding complete stops while the rotor is hot. Note that Tesla regen reduces friction-brake usage, so bedding may take longer than on an ICE vehicle.
• Re-torque lug nuts after 50–100 miles of driving in the star pattern.
• Inspect for fluid leaks at the caliper and brake hose fitting after the first drive.
• While serving brakes, confirm next due dates: brake fluid (every 2 years), cabin air filter (every 2 years; 3 years for HEPA), and tire rotation (every 6,250 mi).

More procedures for this vehicle