Rebuild the rear brake calipers on a 2024 Model X Long Range using a manufacturer-supplied seal/piston rebuild kit. This is a hydraulic brake job — no HV components are involved, but Tesla regen masks brake wear so calipers and slides are often seized from disuse.

Warnings

Tools required

Parts

• Rear brake caliper rebuild kit (piston seal, dust boot, bleeder cap) — manufacturer-specified for Model X rear caliper with integrated EPB × 2 — OEM Tesla rear caliper service kit — verify by VIN
• Caliper slide pin boots (if not included in kit) × 2 — OEM specification
• Brake pad anti-rattle clips (replace if deformed) × 2 — OEM specification
• Copper or aluminum crush washers for banjo fitting (if hose is disconnected) × 4 — OEM specification

Fluids

• DOT 3 Brake Fluid (Tesla-spec) — 1 qt

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Exit ALL doors with 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 in the frunk (similar position to Model S). Remove the frunk liner/cover, disconnect negative terminal first, isolate the cable end.
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 12V: enable Jack Mode via touchscreen (Controls → Service → Jack Mode) so the air suspension does not attempt to self-level.
7. BEFORE disconnecting 12V: use a compatible scan tool to place the rear EPB calipers into service/retract mode. The EPB cannot be retracted manually on this caliper design.
8. Loosen rear lug nuts while wheels are on the ground.
9. Lift rear of vehicle at the manufacturer-designated lift points using a hockey-puck style pad to protect the battery pack. Support on jack stands rated for EV weight.
10. Remove rear wheels.
11. Place a drain pan under each caliper to catch brake fluid.

Procedure

1. 1

   Inspect and document
   Photograph the caliper, brake hose routing, EPB connector path, and pad orientation before disassembly. Note any fluid weeping, torn boots, or scoring on the rotor that indicates a seized piston.
2. 2

   Disconnect EPB electrical connector
   Trace the EPB harness from the rear caliper to the body-side connector. Release the locking tab and disconnect. Free the harness from any retainers on the trailing arm so it does not hang on the caliper during removal.
   ⚠Do not pull on the wires. Release the connector lock fully — the locks are fragile and not separately serviceable.
3. 3

   Disconnect brake hose
   Place a catch pan beneath the caliper. Loosen the brake hose banjo bolt or hose fitting at the caliper, then cap the hose with a brake line plug to minimize fluid loss. Discard the crush washers — they are single-use.
   ⚠Brake fluid will damage paint and aluminum trim. Wipe spills immediately with water.
4. 4

   Remove caliper from bracket
   Remove the two caliper slide bolts and lift the caliper off the bracket. Remove the brake pads and anti-rattle clips. Inspect pads — replace if below 3 mm friction material.
   Torque spec

   Caliper Bolts88 Nm (65 lb-ft)
5. 5

   Remove caliper bracket (optional, for full rebuild)
   If the bracket bolts are corroded or the bracket abutments are rusted, remove the bracket from the rear knuckle. Clean the abutment surfaces with a wire brush. Inspect for cracks. Reinstall on reassembly with threadlocker per OEM specification.
   Torque spec

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

   Extract piston
   With the caliper on a bench, place a wood block in the caliper mouth and use low-pressure compressed air through the brake hose port to walk the piston out. Because the EPB is in service mode, the piston should slide freely. If it does not move, the EPB was not properly retracted — STOP and re-run the scan tool service procedure.
   ⚠️Keep fingers clear of the piston path. A piston launched by compressed air can amputate a finger.
   ⚠Do not use excessive air pressure. If piston will not budge with moderate pressure, the EPB spindle is still engaged.
7. 7

   Remove dust boot and piston seal
   Carefully remove the dust boot and the square-section piston seal from the caliper bore using a non-metallic seal pick. Avoid scratching the bore — any score will cause leaks.
8. 8

   Clean and inspect bore and piston
   Clean the bore and piston with fresh brake fluid or a non-residue brake cleaner approved for hydraulic components. Inspect the bore for pitting, scoring, or corrosion. Inspect the piston (typically phenolic on EPB calipers) for cracks, glazing, or gear-tooth damage on the rear face. Replace the piston if any damage is present — pitted bores are not serviceable; replace the caliper.
   ⚠Do not use petroleum-based solvents in the bore. They will swell and destroy the new seals.
9. 9

   Service slide pins
   Remove slide pins from the caliper bracket. Clean thoroughly. Inspect boots and pins for tears or corrosion — replace if compromised. Re-lubricate with silicone brake grease only (never petroleum grease, which destroys rubber boots).
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Install new seal and dust boot
    Lubricate the new piston seal with clean DOT 3 brake fluid and seat it in the bore groove. Install the new dust boot per the kit instructions (some seat on the piston first, then collapse into the caliper as the piston is inserted). Verify the boot is fully seated in both grooves.
11. 11

    Install piston
    Lubricate the piston with clean brake fluid. Press the piston squarely into the bore by hand or with a caliper piston tool. On EPB calipers, the piston must be installed with the correct rotational orientation so the gear teeth engage the EPB spindle — follow the kit's orientation marking.
    ⚠Forcing the piston in with the wrong orientation will strip the EPB drive teeth.

Reassembly

1. Reinstall the caliper bracket if removed; torque the bracket bolts to specification.
2. Install brake pads and anti-rattle clips into the bracket.
3. Install the caliper over the pads onto the slide pins. Torque caliper bolts to specification.
4. Reconnect the brake hose using NEW crush washers. Torque the banjo bolt to OEM specification — refer to Tesla Service Manual.
5. Reconnect the EPB electrical connector and secure the harness in its retainers.
6. Repeat the rebuild on the opposite rear caliper.
7. Refill the master cylinder reservoir with fresh DOT 3 brake fluid.
8. Bleed the brakes starting at the caliper farthest from the master cylinder. Torque each bleeder screw to specification — do not overtighten, the threads are easy to strip.
9. Consider a full system flush since the system was opened — Tesla recommends DOT 3 fluid replacement every 2 years.
10. Reinstall wheels. Torque lug nuts in a star pattern to specification.
11. Lower the vehicle.
12. Reconnect the 12V battery (positive first, then negative).
13. Use the scan tool to exit EPB service mode and run the EPB calibration/apply-release cycle.
14. Exit Jack Mode via touchscreen.

Verification

• With the vehicle on the ground and 12V reconnected, pump the brake pedal until firm. The pedal must not sink under steady pressure — if it does, there is air in the system or a leak.
• Cycle the EPB on and off several times via the touchscreen or shifter. Listen for the actuator engaging on both rear calipers. Confirm no fault on the instrument cluster.
• Check the touchscreen for any 'Service Brake System,' 'Parking Brake Fault,' or ABS warnings. Clear codes with the scan tool and verify they do not return.
• Inspect each caliper, hose fitting, and bleeder for fluid weeping after a 5-minute pressure hold on the pedal.
• Perform a low-speed (10–15 mph) brake test in a safe area. Confirm even braking with no pull.
• Bed in the pads per the pad manufacturer's procedure if new pads were installed.
• Recheck brake fluid level after the first drive and top up to the MAX line with DOT 3.
• Reset the 2-year brake fluid service interval reminder. Note: Tesla recommends brake fluid replacement every 2 years regardless of mileage.

More procedures for this vehicle