Replacement of a single rear brake rotor on a 2024 Tesla Model S Plaid. The Plaid uses larger performance brakes; this is a standard mechanical job with no HV system involvement, but requires care around the aluminum body and electric parking brake actuator on the rear caliper.

Warnings

Tools required

Parts

• Rear brake rotor (Plaid-spec, verify size by VIN) × 1 — OEM Tesla rear rotor for Model S Plaid — confirm by VIN
• Rotor set screw (if damaged on removal) × 1 — OEM set screw

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 Plaid this is typically the 16V lithium unit located under the rear seat (verify on your specific VIN — some Plaids retain the frunk-mounted 12V). Follow proper isolation procedure.
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 low-voltage power, use a diagnostic tool to place the electric parking brake into service/maintenance mode. Without this step the rear caliper cannot be safely serviced.
7. Loosen (but do not remove) the rear wheel lug nuts while the vehicle is on the ground.
8. Lift the rear of the vehicle using Tesla puck adapters at the manufacturer-specified jack points and support on jack stands rated for EV weight.
9. Remove the rear wheel and inspect the caliper, pads, and rotor for unexpected damage before proceeding.

Procedure

1. 1

   Confirm EPB service mode
   Verify the electric parking brake is in service/transport mode and the caliper piston is retracted/released. If you cannot confirm release, STOP — forcing the caliper off an engaged EPB will destroy the actuator.
   ⚠️Do not pry or force a rear caliper that has not had its EPB released electronically.
2. 2

   Disconnect EPB harness (if caliper removal needed)
   Locate the electric parking brake actuator connector at the rear of the caliper. Release the locking tab and unplug. Tuck the harness aside so it is not strained when the caliper is moved.
3. 3

   Remove caliper from bracket
   Remove the two caliper slide pin/guide bolts securing the caliper body to the bracket. Slide the caliper off the rotor and support it with a hanger or bungee. Do NOT let it hang by any hose or wiring.
   Torque spec

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

   Remove brake pads
   Slide the inner and outer brake pads out of the bracket. Inspect pad thickness and wear pattern; if pads are at or near minimum, replace as a pair.
5. 5

   Remove caliper bracket
   Remove the two caliper bracket bolts that secure the bracket to the rear knuckle. These are high-torque fasteners — use a breaker bar. Remove the bracket and set aside.
   ⚠Bracket bolts are torqued high from the factory and may have threadlocker. Apply steady force; do not let the wrench slip and damage the aluminum knuckle area.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
6. 6

   Remove rotor set screw
   Remove the small Torx/hex set screw retaining the rotor to the hub. If the screw head is corroded or stripped, take care not to round it — apply penetrating oil and use the correct bit. A replacement screw is recommended on reassembly if it shows damage.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
7. 7

   Remove old rotor
   Pull the rotor off the hub. If seized due to corrosion at the hub center, tap gently around the rotor hat with a dead-blow mallet, or thread bolts into the rotor's removal-threaded holes (if equipped) to push it off the hub. Do NOT strike the hub or knuckle with a steel hammer.
   ⚠Aluminum suspension components — do not pry against or strike the knuckle.
8. 8

   Clean hub mating surface
   Wire-brush the hub face until clean and free of rust/scale. A clean, flat mating surface is essential to prevent rotor runout and brake pulsation. Apply a very thin smear of anti-seize to the hub center pilot only — keep all anti-seize and lubricants off the rotor friction surfaces and wheel studs.
9. 9

   Install new rotor
   Wipe the new rotor's friction surfaces with brake cleaner to remove shipping oil. Place the rotor on the hub, aligning the set screw hole, and install the set screw to retain it during caliper installation.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
10. 10

    Reinstall caliper bracket
    Position the caliper bracket on the knuckle. Install the caliper bracket bolts. If the original bolts had threadlocker and are being reused, apply fresh medium-strength threadlocker per OEM specification. Torque to spec.
    Torque spec

    Bracket Bolts102 Nm (75 lb-ft)
11. 11

    Install pads and caliper
    Reinstall the brake pads into the bracket (with any anti-rattle clips/shims in their original positions). Confirm the caliper piston is fully retracted (it should be from EPB service mode). Slide the caliper over the rotor and pads. Apply a small amount of silicone brake grease to the slide pins. Install and torque the slide pin bolts.
    ⚠Do not get any grease on the rotor friction surface or pad friction material.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
12. 12

    Reconnect EPB connector
    Reconnect the electric parking brake harness to the caliper actuator. Confirm the connector is fully latched and the harness is routed clear of the rotor and suspension travel.

Reassembly

1. Reinstall the rear wheel. Hand-thread all lug nuts before applying torque.
2. Lower the vehicle until the tire just contacts the ground, then torque the lug nuts in a star pattern.
3. Reconnect the low-voltage battery.
4. Use the diagnostic tool to take the electric parking brake out of service mode and re-calibrate the EPB if required.
5. With the vehicle stationary and your foot firmly on the brake pedal, cycle the brake pedal several times to seat the pads against the rotor before driving.
6. Cycle the EPB on/off several times via the touchscreen / shifter and listen for normal actuator operation.

Verification

• Confirm no warning messages on the touchscreen related to ABS, EPB, traction control, or vehicle dynamic systems.
• At very low speed (5–10 mph) in a safe area, test light braking — pedal should be firm with no pulsation or pulling.
• Perform a proper bed-in procedure for the new rotor (manufacturer-recommended sequence of moderate stops from ~30 mph) before any aggressive driving.
• After 50–100 miles, re-check wheel lug torque using the verified spec in a star pattern.
• Visually inspect the rotor friction surface after the first drive — even contact patch across the rotor confirms proper caliper alignment and hub mating.
• Note: Tesla recommends brake fluid replacement every 2 years regardless of mileage — if not done recently, schedule a flush. Also confirm tire rotation interval (~6,250 mi) is up to date while the wheels are off.

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