Replace a rear brake hose on a 2024 Model X Long Range. The job involves opening the hydraulic system, so a complete brake fluid bleed and DOT 3 fluid top-off are mandatory afterward.

Warnings

Tools required

Parts

• Rear brake hose assembly (manufacturer-specified for 2024 Model X) × 1 — OEM Tesla rear brake hose — verify by VIN
• Copper sealing washers for banjo fitting × 2 — New crush washers — sized to match banjo bolt

Fluids

• DOT 3 Brake Fluid (Tesla-specified) — 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 12V low-voltage battery, located in the frunk (similar position to Model S). Remove the frunk trim/cover as required to access it.
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 the 12V is disconnected, enable Jack Mode on the touchscreen so the air suspension does not attempt to ride-height correct.
7. Loosen rear lug nuts while the wheel is still on the ground.
8. Lift the rear of the vehicle on Tesla-approved puck points and support on rated jack stands. Never trust the air suspension or jack alone.
9. Remove the rear wheel on the affected side.
10. Verify brake fluid reservoir level and have fresh, sealed DOT 3 fluid ready before opening the hydraulic system.

Procedure

1. 1

   Inspect and document the hose routing
   Photograph the existing brake hose routing, the bracket attachment, the caliper banjo orientation, and the hard-line union at the chassis end. Correct routing is essential to prevent contact with the suspension during full droop or steering articulation.
2. 2

   Cap the master cylinder reservoir
   Open the frunk and place a sealed bag or proper cap over the brake fluid reservoir to slow fluid loss via siphoning while the line is open. Do not let the reservoir run dry during the job.
   ⚠If the reservoir empties, air will enter the iBooster/ABS module and a more involved bleed procedure may be required.
3. 3

   Loosen the hard-line fitting at the chassis end
   Using a flare-nut wrench, break loose (do not fully remove yet) the hard brake line nut threading into the upper end of the flexible hose. Use a second wrench on the hose hex to prevent twisting the hose body.
   ⚠Never use an open-end wrench on hydraulic line nuts — it will round them. Flare-nut wrench only.
4. 4

   Remove the hose retaining clip and bracket
   Remove the U-clip securing the upper end of the flexible hose to the chassis bracket, then unbolt the brake hose support bracket if a bolt is used at the body or suspension routing point.
   Torque spec

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

   Disconnect the upper (chassis) end of the hose
   Fully unthread the hard line from the flexible hose. Immediately cap the hard line with a clean plug to minimize fluid loss and contamination. Drain residual fluid from the hose into a catch bottle.
   ⚠Fluid will drip onto the rear subframe and HV pack underbody shielding. Catch and wipe immediately.
6. 6

   Remove the banjo bolt at the caliper
   Support the caliper if needed. Unscrew the banjo bolt at the rear caliper inlet and separate the hose from the caliper. Discard both copper sealing washers — they must be replaced with new ones. Cap the caliper port.
   ⚠Do not reuse copper washers. Reused washers commonly weep and will fail a road test.
7. 7

   Remove the old hose
   Withdraw the hose from any routing brackets or grommets and remove from the vehicle. Compare length, end fittings, and bracket tabs against the new hose before installation.
8. 8

   Install the new hose at the caliper
   Place a new copper washer on each side of the banjo fitting (one between bolt head and fitting, one between fitting and caliper). Hand-thread the banjo bolt to avoid cross-threading, then torque to spec. Verify the hose's natural orientation matches the original — the hose must not be twisted.
   ⚠A twisted hose will chafe through within months. Confirm the routing is identical to the photo taken in Step 1.
   Torque spec

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

   Connect the upper end and re-secure the bracket
   Thread the hard-line flare nut into the new hose by hand to confirm clean engagement, then tighten with a flare-nut wrench while holding the hose hex. Reinstall the U-clip at the chassis bracket. Reinstall the hose support bracket bolt and torque to spec.
   ℹ️Hard line flare nut torque: torque to OEM specification — refer to Tesla Service Manual.
   Torque spec

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

    Bleed the rear brake circuit
    Top up the reservoir with fresh DOT 3 fluid. Bleed the affected rear caliper at the bleeder screw using a pressure or vacuum bleeder, or a two-person pedal method. Continue until clear, bubble-free fluid flows. Tesla recommends a full system flush every 2 years — consider bleeding all four corners now.
    ⚠Keep reservoir topped up throughout the bleed. Do not allow it to drop below MIN.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
11. 11

    Pressure-test for leaks
    With the bleeder closed, have an assistant firmly press and hold the brake pedal while you inspect the banjo fitting and chassis-end union for any seepage. Repeat after 30 seconds of held pressure.

Reassembly

1. Verify reservoir is filled to MAX with fresh DOT 3 fluid and reinstall the cap.
2. Reinstall the rear wheel. Snug lug nuts in a star pattern.
3. Lower the vehicle to the ground.
4. Final-torque lug nuts in a star pattern to spec.
5. Reconnect the 12V battery in the frunk and reinstall any trim removed for access.
6. Close the frunk.
7. Sit in the vehicle with the fob, wake the car, and exit Jack Mode (the suspension will re-level).

Verification

• Before the first drive: with the vehicle awake and brakes powered (iBooster active), pump the pedal several times — it must build firm resistance and not sink.
• Inspect the banjo bolt and chassis-end union one more time after pedal pressure cycling — no weeping permitted.
• Check the touchscreen for any ABS, traction control, or brake-related alerts. Any active alert means the system has air or a sensor disconnect — do not drive.
• Perform a low-speed (10-15 mph) brake test in a safe area before normal driving. Pedal feel should be firm and equal to pre-service.
• Recheck reservoir level and inspect the hose connections for leaks after a short test drive.
• Log this service: Tesla recommends DOT 3 brake fluid replacement every 2 years regardless of mileage. Reset your 2-year interval from today's date.

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