Replace both front brake rotors on a 2024 Model S Plaid. The Plaid uses upgraded high-performance front brakes with larger rotors and fixed multi-piston calipers, which changes the procedure compared to standard Model S — the caliper itself is unbolted from the knuckle rather than swung open on slide pins.

Warnings

Tools required

Parts

• Front brake rotors (Model S Plaid spec — verify size by VIN, Plaid uses larger front rotors than base Model S) × 2 — OEM Tesla Model S Plaid front rotor — match by VIN
• Rotor set screws (replace if damaged) × 2 — OEM specification

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 the 16V lithium unit; verify location per VIN (frunk under nose cowl, or under rear seat on some Plaid builds).
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 — this is REQUIRED on Plaid air suspension.
7. Loosen front wheel lug nuts while the vehicle is on the ground.
8. Lift the front of the vehicle at Tesla-specified jack points using approved pucks. Support on jack stands rated for EV curb weight.
9. Remove both front wheels and set aside on their faces to protect finish.

Procedure

1. 1

   Inspect brake assembly before disassembly
   Photograph the caliper, brake line routing, and any wear sensor wiring before removal. Inspect pads for thickness and rotor for scoring, lip, heat checking, or cracking. Plaid rotors are large two-piece designs — confirm replacement rotors match OEM size and offset exactly.
2. 2

   Disconnect pad wear sensor (if equipped)
   If the front pads have a wear sensor lead, unclip it from the caliper and free it from any chassis retainers. Do not pull on the wire.
3. 3

   Remove brake pads (Plaid fixed caliper)
   On the Plaid front fixed caliper, remove the pad retaining pin clip and slide out the retaining pin(s), then withdraw the brake pads from the caliper body. Note pad orientation. This allows the caliper to clear the new rotor without needing to retract pistons aggressively. If pads are being reused, mark them inner/outer and left/right.
   ⚠Do not press the brake pedal at any point with pads removed — pistons can extrude past their seals.
4. 4

   Unbolt the caliper from the knuckle
   Remove the two caliper-to-knuckle mounting bolts. These are the large bolts securing the fixed caliper body to the steering knuckle. Support the caliper as the second bolt comes free. Hang the caliper from the coil/strut tower with wire or a bungee — do NOT let it hang by the brake hose.
   ⚠Caliper is heavy on Plaid — use two hands and have the support strap ready before fully removing the second bolt.
   Torque spec

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

   Remove rotor set screw
   Remove the small Torx/hex set screw retaining the rotor to the hub face. If seized, use an impact driver — these strip easily. Replace the screw if the head is damaged.
   Torque spec

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

   Remove the rotor
   Pull the rotor straight off the hub. If stuck due to corrosion at the hub register, thread two bolts into the rotor's 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 — impact damage can necessitate suspension component replacement.
7. 7

   Clean the hub face
   Wire-brush the hub mounting face and pilot until bare, smooth metal is exposed. Any rust or debris will cause rotor runout and brake pulsation. A very thin film of anti-seize on the hub face only (not on lug studs or wheel mating surface) helps future serviceability.
8. 8

   Install new rotor
   Remove protective coating from new rotor with brake cleaner — both faces. Slide rotor onto the hub, aligning the set screw hole. Install set screw and torque to spec.
   Torque spec

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

   Reinstall caliper
   Position the fixed caliper over the new rotor, aligning with the knuckle bolt holes. Apply medium-strength threadlocker to the caliper-to-knuckle bolts (unless they are pre-coated single-use bolts — refer to Tesla Service Manual; if single-use, replace them). Hand-thread both bolts before torquing to spec in a cross pattern.
   ⚠Verify whether OEM bolts are single-use torque-to-yield — refer to Tesla Service Manual before reusing.
   Torque spec

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

    Reinstall pads and retaining hardware
    Slide pads back into the caliper in original orientation (or new pads with friction material facing the rotor). Install pad retaining pin and clip. Reconnect wear sensor lead if equipped.
11. 11

    Repeat on opposite side
    Perform steps 1–10 on the other front wheel. Always replace front rotors as a pair.
12. 12

    Seat the pads against the new rotors
    Before lowering the vehicle, with the wheels still off, slowly press the brake pedal multiple times until firm to seat the pads against the new rotors. The first pump will feel soft — this is normal on fixed calipers after pad removal.
    ⚠Do not drive the vehicle until the pedal is firm at the top of its travel.

Reassembly

1. Reinstall front wheels. Hand-thread all lug nuts before applying torque to avoid cross-threading aluminum-friendly hubs.
2. Lower the vehicle to the ground.
3. Torque wheel lug nuts in a star pattern to spec.
4. Reconnect the low-voltage battery.
5. Exit Jack Mode via the touchscreen and allow air suspension to re-level.
6. Clear any chassis/ABS faults that may have set during the 12V disconnect by cycling the vehicle through a full sleep/wake.

Verification

• With vehicle still stationary, confirm a firm brake pedal at the top of travel — no sponginess.
• Check the touchscreen for any active brake, ABS, or stability control alerts. Plaid will display chassis warnings if a wheel speed sensor was disturbed.
• Perform a low-speed brake test in a safe area: 5-10 mph stops, checking for pulling, noise, or pulsation.
• Bed-in the new rotors per Tesla/pad manufacturer procedure: typically 6-10 moderate stops from ~35 mph to ~5 mph without coming to a complete stop, then drive several minutes to cool. Note: regen braking will limit pad usage during bed-in — use Hold mode or apply firmer pedal pressure to override regen.
• After 50-100 miles, re-torque wheel lug nuts.
• If vehicle is at or past 2 years since last brake fluid service, schedule DOT 3 brake fluid replacement per Tesla's 2-year interval recommendation.
• Confirm Jack Mode has exited and air suspension self-leveling is active before normal driving.

More procedures for this vehicle