Replace a rear brake caliper on a 2024 Tesla Model X Plaid. The procedure is mechanically similar to other modern vehicles, but requires Tesla-specific air suspension handling and electric parking brake (EPB) service mode activation before work begins.

Warnings

Tools required

Parts

• Rear brake caliper assembly (manufacturer-specified for Model X Plaid) × 1 — Tesla OEM rear caliper — left or right side as applicable
• Copper crush washers for brake hose banjo fitting × 2 — OEM-spec copper washers, sized to banjo bolt
• Brake pads (inspect; replace if worn or contaminated) × 1 — OEM rear pad set
• Threadlocker (medium strength, blue) × 1 — Loctite 243 or equivalent

Fluids

• DOT 3 Brake Fluid (sealed, fresh container) — 1 qt

Preparation

1. Park on level ground, place in P, and engage the 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. Be aware of the falcon-wing rear doors — ensure they are fully closed and that nothing in your work area will obstruct them if they are commanded open.
4. Place the vehicle in Jack Mode via the touchscreen to disable air suspension self-leveling (Controls > Service > Jack Mode).
5. Activate Brake Service Mode / EPB Maintenance Mode on the touchscreen so the electric parking brake actuator retracts and disables. Confirm the EPB has released.
6. Disconnect the 12V low-voltage battery in the frunk (similar location to Model S). Wait 2 minutes after disconnection before proceeding.
7. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal.
8. 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.
9. Loosen rear lug nuts while the wheel is still on the ground.
10. Lift the vehicle using only Tesla-approved jack pad locations with proper pucks, and support on rated jack stands.
11. Remove the rear wheel on the affected side.

Procedure

1. 1

   Confirm EPB is released and disconnected
   Verify that the electric parking brake actuator on the rear caliper is fully released (Service Mode active and 12V disconnected). If the EPB motor still has power, attempting to retract the piston mechanically will destroy the actuator gear set.
   ⚠Never retract a Tesla rear caliper piston with the EPB live — it must be in service mode and the 12V disconnected.
2. 2

   Position fluid catch pan and pre-loosen banjo bolt
   Place a catch pan beneath the caliper. Crack loose (do not remove) the brake hose banjo bolt at the caliper to confirm the fitting will release. Re-snug it before removing the caliper bolts to limit drips.
3. 3

   Disconnect EPB actuator electrical connector
   Locate the EPB harness connector on the rear caliper. Release the connector lock and unplug the harness. Move the harness aside and protect the connector from contamination.
   ⚠Do not pull on the wire — release the locking tab and pull on the connector body only.
4. 4

   Remove brake pads (if reusing)
   If the existing pads are serviceable and you intend to reuse them, remove the pad retaining hardware and slide the pads out. Inspect for contamination from brake fluid; if contaminated, replace them.
5. 5

   Remove caliper guide/slide bolts
   Remove the caliper-to-bracket bolts (caliper slide bolts) and lift the caliper body off the bracket. Support the caliper to avoid hanging it by the brake hose.
6. 6

   Disconnect brake hose at caliper
   Position the catch pan, then remove the banjo bolt at the caliper. Discard the two copper crush washers — they must be replaced with new ones on reassembly. Cap or plug the hose end to minimize fluid loss and contamination.
   ⚠Brake fluid will drip — protect paint and suspension bushings.
7. 7

   Remove caliper bracket (if replacing as an assembly)
   If the replacement caliper comes with a bracket, remove the two caliper bracket-to-knuckle bolts. These are high-torque fasteners with threadlocker — anticipate significant breakaway force.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
8. 8

   Inspect rotor and hub mating surface
   With the caliper off, inspect the rotor surface and the hub-rotor interface. Clean any rust or debris. Verify the rotor is within service spec; if not, address before installing the new caliper.
9. 9

   Install new caliper bracket
   Apply a small amount of medium-strength threadlocker to the caliper bracket bolt threads. Install the bracket and torque to specification.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
10. 10

    Connect brake hose to new caliper
    Install the brake hose to the new caliper using TWO new copper crush washers (one on each side of the banjo fitting). Hand-thread the banjo bolt first to avoid cross-threading, then torque to specification. Ensure the hose is not twisted and routes naturally.
    ⚠Always use new copper washers — reusing old washers will cause a slow leak.
11. 11

    Install pads and mount caliper
    Install brake pads into the bracket per the manufacturer's orientation. Position the caliper body over the pads and rotor, then install the caliper slide/mounting bolts and torque to specification.
12. 12

    Reconnect EPB actuator harness
    Plug the EPB connector back into the new caliper actuator. Confirm the locking tab is fully seated. Route the harness in its original path and secure any clips.
13. 13

    Bleed the rear brake circuit
    With a helper or vacuum bleeder, bleed the caliper at the bleeder screw until clean, bubble-free DOT 3 fluid flows. Maintain reservoir level above MIN throughout. Torque the bleeder screw — do NOT overtighten, as the bleeder is easily damaged. Refer to the Tesla Service Manual for the correct full-vehicle bleed sequence if a complete bleed is required.
    ⚠Tesla recommends DOT 3 brake fluid — do not substitute DOT 5 silicone fluid.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)

Reassembly

1. Verify the brake fluid reservoir is filled to the correct level with fresh DOT 3 fluid.
2. Reinstall the rear wheel and hand-tighten the lug nuts in a star pattern.
3. Lower the vehicle to the ground.
4. Final-torque the lug nuts in a star pattern to specification.
5. Reconnect the 12V low-voltage battery in the frunk.
6. Power the vehicle on; the touchscreen may display brake-related alerts. Exit Jack Mode and exit Brake Service Mode through the touchscreen so the EPB calibrates and re-engages.
7. With the vehicle stationary and in P, cycle the parking brake several times via the touchscreen to seat the EPB actuator and confirm proper operation.
8. With the vehicle still stationary, pump the brake pedal until firm before any movement.

Verification

• Brake pedal must feel firm on the first press — a soft or sinking pedal indicates air in the system; re-bleed.
• No fluid weeping at the banjo fitting or bleeder after several firm pedal applications.
• No brake-related warnings on the instrument cluster/touchscreen after a full power cycle.
• Confirm the EPB engages and releases via the touchscreen control with no fault messages and no unusual noise from the actuator.
• Perform a low-speed (<10 mph) brake test in a safe area, then a moderate-speed test, checking for pull, drag, or noise.
• Inspect the caliper, hose, and bleeder for leaks after the test drive.
• Tesla recommends brake fluid replacement every 2 years regardless of mileage — log this service date and consider a full system flush if the existing fluid is older than 2 years.

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