Replace both rear brake rotors on a 2024 Model S Plaid. The Plaid uses larger performance brakes than standard Model S, but the rear rotor R&R follows a conventional caliper-bracket-rotor sequence with no HV system involvement.

Warnings

Tools required

Parts

• Rear brake rotors (Model S Plaid-spec, performance) × 2 — Tesla OEM or equivalent performance-grade rotor matched to Plaid rear caliper
• Rotor set screws (replace if damaged on removal) × 2 — OEM set screw, M6 Torx as supplied

Preparation

1. Park on level ground, place in P, engage parking brake via the touchscreen.
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 located under the rear seat (verify by VIN — some Plaid units retain the front frunk-mounted 12V). Remove negative terminal first.
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. In the touchscreen (before LV disconnect): disable Sentry Mode, Cabin Overheat Protection, and put the vehicle in Service Mode if available — this prevents air suspension from auto-leveling while on stands.
7. If equipped with air suspension (standard on Plaid), set ride height to Standard and enter Jack Mode via Controls > Service > Jack Mode to disable auto-leveling.
8. Loosen rear lug nuts 1/4 turn while wheels are on the ground.
9. Lift the rear of the vehicle at the manufacturer-specified rear lift points using rubber pucks; support on jack stands rated for the vehicle weight.
10. Remove both rear wheels.

Procedure

1. 1

   Inspect before disassembly
   Visually inspect both rear calipers, pads, rotors, and dust shields. Photograph the brake hose routing and any wear sensor leads (if equipped) so they can be reinstalled identically. Check pad thickness — Plaid rear pads often outlast rotors due to heavy regen use.
2. 2

   Compress the caliper piston
   Open the brake fluid reservoir cap in the frunk and check level — compressing the piston will push fluid back. Using a C-clamp or piston spreader, gently retract the rear caliper piston into its bore to create clearance for new (thicker) rotor and pads. On Plaid, the rear caliper is electrically actuated for the parking brake; do NOT force the piston by rotating — use only linear compression, or place the vehicle in Service Mode to retract the EPB actuator electronically before LV disconnect.
   ⚠The rear calipers incorporate the electric parking brake. If the EPB was not retracted via Service Mode before LV disconnect, you may need to reconnect the LV battery, retract via Service Mode, then disconnect again.
3. 3

   Remove the caliper
   Remove the two caliper slide pin bolts (or guide bolts) securing the caliper body to the bracket. Slide the caliper off the rotor. Support the caliper with a hanger or bungee from the suspension — do NOT let it hang by the flexible brake hose.
   Torque spec

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

   Remove the caliper bracket
   Remove the two caliper bracket bolts securing the bracket to the rear knuckle. These are torqued tight and may have factory threadlocker — use a breaker bar. Set the bracket aside in a clean area.
   Torque spec

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

   Remove the rotor set screw and rotor
   Remove the small Torx set screw retaining the rotor to the hub. If the rotor is rust-bonded to the hub, apply penetrating oil to the hat area and tap gently with a dead-blow mallet around the hat — never strike the friction surface or the aluminum knuckle. If the rotor has threaded jacking holes, thread bolts in evenly to break it free.
   ⚠Aluminum knuckle and hub — do NOT strike with a steel hammer. Use only a dead-blow or rubber mallet.
   Torque spec

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

   Clean the hub face
   Wire-brush the hub face to remove all rust and debris. A clean, flat hub face is critical to prevent rotor lateral runout, which causes brake pedal pulsation. A very thin film of anti-seize may be applied to the hub center pilot only — keep all anti-seize off the rotor friction surface and the wheel mounting face.
7. 7

   Install the new rotor
   Wipe the new rotor's friction surfaces with brake cleaner to remove the protective coating. Mount the new rotor over the wheel studs and seat fully against the hub. Install the rotor set screw and snug it down.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
8. 8

   Reinstall the caliper bracket
   Inspect bracket bolts; if reusing, clean threads and apply blue threadlocker. Install the bracket onto the knuckle and torque to specification.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
9. 9

   Inspect pads and slide pins
   Inspect existing rear pads — if friction material is below 3 mm, replace as a pair (rear pads typically last well on Plaid due to regen, but verify). Clean and re-grease the caliper slide pins with silicone brake grease. Inspect the rubber boots for tears.
10. 10

    Reinstall the caliper
    Slide the caliper over the new rotor and pads. Install the caliper slide pin bolts and torque to specification. Confirm the caliper moves freely on its slides and the pads are properly seated against the rotor.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
11. 11

    Repeat on the opposite side
    Perform steps 2 through 10 on the other rear corner. Always replace rear rotors as a pair to maintain even braking.
12. 12

    Reinstall wheels
    Mount the rear wheels. Hand-thread all lug nuts, then snug in a star pattern. Lower the vehicle so tires just contact the ground, then final-torque the lug nuts to specification in a star pattern.
    ⚠Tesla recommends re-torqueing lug nuts after the first 50–100 miles of driving following any wheel removal.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Lower the vehicle fully to the ground.
2. Verify brake fluid reservoir is at the MAX line; top up with the DOT 3 or DOT 4 brake fluid specified for this VIN if needed.
3. Reconnect the low-voltage (16V or 12V) battery — negative terminal last.
4. Close the frunk and ensure all doors close normally (auto-presenting handles may need a cycle to re-learn).
5. Exit Jack Mode / Service Mode in the touchscreen.
6. Allow the air suspension (if equipped) to re-level before driving.
7. With the vehicle stationary and parking brake released, pump the brake pedal firmly several times until it becomes firm — this seats the new rotor against the pads and re-extends the caliper piston.
8. Re-check brake fluid level after pedal pumping.

Verification

• Confirm a firm brake pedal before driving — never drive if the pedal sinks to the floor.
• Check the touchscreen for any brake, ABS, traction control, or EPB warning lamps. The Plaid will throw a 'Service Vehicle Soon' or specific brake fault if the EPB is not properly homed; cycle the parking brake from the touchscreen to re-engage.
• At low speed in an empty area, perform several gentle stops from 10–15 mph to confirm normal braking with no pull, vibration, or noise.
• Bed in the new rotors per the rotor manufacturer's procedure (typically 6–10 moderate stops from 35 mph to 5 mph without coming to a complete stop, then a cool-down). Note: aggressive regen on Plaid means brake bedding requires deliberate friction-brake use — set regen to Low temporarily if needed.
• After the first 50–100 miles, re-torque the lug nuts in a star pattern.
• Service reminder: Tesla recommends brake fluid replacement every 2 years regardless of mileage. If due, perform a full bleed using DOT-spec fluid per VIN — torque bleeder screws to specification.
• Service reminder: Tesla recommends tire rotation every 6,250 miles on Model S Plaid due to high torque and weight.

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