Replace a front brake caliper on a 2024 Model X Plaid. The Plaid uses high-performance front calipers with larger rotors than standard Model X; this job involves opening the hydraulic system and therefore requires brake bleeding afterward.

Warnings

Tools required

Parts

• Front brake caliper (Model X Plaid-specific) × 1 — Tesla OEM front caliper for Model X Plaid — left or right side as applicable
• Copper crush washers for banjo fitting × 2 — OEM-spec copper sealing washers, sized to caliper banjo bolt
• Brake pads (inspect/replace if worn or contaminated) × 1 — Tesla Model X Plaid front pad set

Fluids

• DOT 3 Brake Fluid (sealed container) — 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. Open the frunk and disconnect the 12V low-voltage battery (negative terminal first). Refer to architecture notes — 12V is in the frunk on Model X.
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' on the touchscreen (Service menu) so the air suspension does not attempt to re-level while the vehicle is lifted.
7. Confirm the falcon doors are fully closed and will remain closed — keep the key fob outside the working area.
8. Loosen the front wheel lug nuts while the vehicle is on the ground.
9. Lift the front of the vehicle at the factory-designated lift points using Tesla-approved jack pucks. Support with rated jack stands. Never rely on the jack alone.
10. Remove the front wheel and set aside on its sidewall.

Procedure

1. 1

   Inspect and stage the work area
   Visually inspect the existing caliper, pads, rotor, and brake hose for damage, leaks, or contamination. Note the orientation of the hose and any anti-rotation features so the new caliper is installed identically. Position a fluid catch container under the caliper.
2. 2

   Relieve hydraulic pressure and prepare the hose connection
   With the 12V disconnected, the iBooster/brake controller is unpowered. Clean the banjo fitting at the caliper thoroughly with brake cleaner so no debris enters the hydraulic system. Have rags ready — fluid will drip when the line is opened.
   ⚠Do not press the brake pedal while the system is open. On Tesla, the iBooster can self-actuate when 12V is connected; keep it disconnected throughout.
3. 3

   Disconnect the brake hose from the caliper
   Unscrew the banjo bolt at the caliper. Capture both copper crush washers (one on each side of the banjo fitting) — these MUST be replaced with new ones. Cap or plug the hose end immediately to minimize fluid loss and air ingress.
   ⚠Cover painted bodywork and the front fender liner. Brake fluid will run down the hose and damage paint.
4. 4

   Remove the caliper guide/slider bolts
   Remove the caliper-to-bracket bolts (the bolts that secure the caliper body to the caliper bracket). Slide the caliper off the rotor. If reusing the bracket, leave it bolted to the knuckle. If you are replacing a fixed-mount Plaid caliper that bolts directly to the knuckle (no separate bracket), proceed to step 5 instead.
5. 5

   Remove the caliper bracket from the knuckle (if equipped)
   If the caliper assembly mounts via a bracket to the steering knuckle, remove the two caliper bracket bolts. The Model X Plaid front caliper is a large multi-piston unit — support its weight as the last bolt comes out. Do not let the caliper hang by any line.
   ⚠The Plaid front caliper is heavy. Use a caliper hanger or have an assistant support it during removal.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
6. 6

   Transfer pads (if reusing) and inspect the rotor
   If brake pads are within service spec and not contaminated, transfer them to the new caliper following the manufacturer's pad orientation. Otherwise install new pads. Inspect the rotor for scoring, heat checking, and minimum thickness — the Plaid uses high-performance rotors and any contamination from a leaking caliper warrants pad replacement at minimum.
7. 7

   Install the new caliper assembly
   Position the new caliper (and bracket if applicable) onto the knuckle. Apply medium-strength threadlocker to the bracket bolts if specified by the replacement part instructions. Torque the bracket-to-knuckle bolts first, then install the caliper body and torque those bolts.
   ℹ️Verify final torque sequence and any updated values against the current Tesla Service Manual entry for Model X Plaid front brake.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
8. 8

   Reconnect the brake hose with new copper washers
   Install NEW copper crush washers on both sides of the banjo fitting. Hand-thread the banjo bolt to confirm clean engagement, then torque to spec. Verify the hose is not twisted and clears suspension travel.
   ⚠️Reusing copper washers or omitting them will cause a brake fluid leak and brake failure.
9. 9

   Bleed the brake caliper
   Top off the brake fluid reservoir in the frunk with fresh DOT 3. Reconnect 12V temporarily ONLY if you need iBooster-assisted bleeding — otherwise use a pressure or vacuum bleeder on the caliper bleeder screw with 12V still disconnected. Bleed until clear, bubble-free fluid emerges. Tesla typically requires a service-tool-driven iBooster bleed for a complete flush; for a single-caliper service a manual/pressure bleed of that corner is generally sufficient if no air entered the master cylinder.
   ⚠Do not overtighten the bleeder screw — it is a small fastener and easily snapped off.
   ℹ️If the pedal feels spongy after bleeding, a full Tesla Toolbox iBooster bleed procedure may be required. Stop and consult a Tesla-certified technician before driving.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
10. 10

    Final fluid level check and leak test
    Top the reservoir to the MAX line with fresh DOT 3. Wipe the caliper and banjo fitting dry. Reconnect 12V (negative last). With the vehicle still elevated, press the brake pedal firmly multiple times and inspect the banjo fitting and bleeder screw for any seepage.

Reassembly

1. Reinstall the front wheel. Hand-thread all lug nuts before applying torque.
2. Lower the vehicle to the ground.
3. Torque the wheel lug nuts in a star pattern.
4. Exit Jack Mode via the touchscreen and allow the air suspension to re-level.
5. Top off the brake fluid reservoir in the frunk to the MAX line if needed.
6. Re-verify the banjo bolt and bleeder screw are dry.

Verification

• With the vehicle stationary and brake pedal pressed, confirm a firm pedal with no slow sink. A spongy or sinking pedal indicates trapped air or a leak — do not drive.
• Check the touchscreen for any brake-system, ABS, or stability control alerts after reconnecting 12V.
• Roll-test at very low speed in a safe area: confirm the vehicle pulls straight under light braking and there is no grinding, dragging, or pulsing.
• After 25-50 miles, re-inspect the banjo fitting and bleeder for weeping fluid and re-check pedal feel.
• Record this service date for the 2-year brake fluid interval Tesla recommends — a full flush may be due if it has been more than 2 years since last service.
• Confirm falcon door operation is normal after 12V reconnection (door calibration is occasionally affected by 12V disconnects).

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