Replacement of a single hydraulic brake line on a 2024 Model X Plaid. The procedure requires careful handling of DOT 3 brake fluid (corrosive to paint and aluminum body panels) and a full system bleed afterward.

Warnings

Tools required

Parts

• Replacement brake line (manufacturer-specified for affected corner/section) × 1 — Tesla OEM brake line — match by VIN and position
• Copper sealing washers (if banjo-style fitting) × 2 — OEM specification
• Brake line retaining clips × 1 — OEM specification — replace if damaged on removal

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). This also prevents accidental falcon door operation while you work.
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 the 12V, enter Jack Mode on the touchscreen to disable air suspension self-leveling (Controls > Service > Jack Mode). Confirm the suspension setting is locked before powering down.
7. Identify the failed brake line and confirm which corner/section is affected. Note the routing path and all retaining clip locations before removal.
8. Inspect the brake fluid reservoir level in the frunk and top up only with fresh DOT 3 if low.
9. Have a fluid catch pan and absorbent towels ready at the line endpoints before opening any fitting.

Procedure

1. 1

   Lift vehicle and remove wheel
   With Jack Mode active, lift the affected corner using only Tesla-approved jack pad pucks at the designated lift points. Support the vehicle on rated jack stands. Remove the wheel by loosening the lug nuts in a star pattern.
   ⚠Never lift a Model X without Jack Mode engaged — the air suspension will fight the jack.
2. 2

   Position drain pan and protect surrounding components
   Place a brake fluid catch pan beneath the work area. Cover any nearby aluminum body panels, painted surfaces, and rubber suspension bushings with shop towels or plastic sheeting to protect from drips.
3. 3

   Loosen brake line fittings
   Using a flare-nut (line) wrench, carefully crack loose the fittings at both ends of the brake line to be replaced. If the line connects to a flexible hose, hold the hex of the hose end with a backup wrench to prevent twisting the hose. Do not fully remove fittings yet.
   ⚠A standard open-end wrench will round these fittings. Use a flare-nut wrench.
4. 4

   Release retaining clips
   Locate and release all brake line retaining clips and brackets along the line's routing. Note their positions and orientation. Replace any clips that are damaged or brittle on reassembly.
5. 5

   Disconnect and remove the failed brake line
   Fully unthread the fittings at both ends, allowing the line to drain into the catch pan. Remove the line from the vehicle, taking note of the exact routing path for the replacement. Cap or plug the open ports immediately to prevent contamination and excessive fluid loss from the master cylinder reservoir.
   ⚠Monitor the master cylinder reservoir in the frunk — do not let it run dry, or you will need to bleed the ABS/iBooster module, which requires Tesla Toolbox software.
6. 6

   Compare and prepare new brake line
   Compare the new line to the old one for length, bend pattern, and fitting type. Confirm it matches exactly. If using a banjo fitting, install fresh copper sealing washers on both sides of the banjo bolt.
7. 7

   Install new brake line
   Route the new line along the original path. Hand-thread both end fittings first to avoid cross-threading, then snug them with a flare-nut wrench. Reinstall all retaining clips and brackets in their original positions.
   ⚠Cross-threaded fittings are the #1 cause of repeat leaks. Always start threads by hand.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
8. 8

   Final tighten fittings to OEM specification
   Tighten both brake line end fittings to manufacturer specification. Torque to OEM specification — refer to Tesla Service Manual for the specific fitting type used at this location.
9. 9

   Refill master cylinder and bleed the system
   Top up the brake fluid reservoir with fresh DOT 3. Bleed the affected corner using your preferred method (pressure, vacuum, or two-person pedal method). Open the bleeder screw, allow fluid to flow until clean, bubble-free fluid emerges, then close. Repeat until firm pedal is achieved. Keep the reservoir topped up throughout.
   ⚠If air enters the ABS/iBooster module (reservoir ran dry), a full system bleed via Tesla Toolbox is required. Stop and seek a certified technician.
   Torque spec

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

    Pressure test for leaks
    With the system bled and reservoir topped to the MAX line, have an assistant firmly hold the brake pedal while you inspect every joint of the new line for weeping or drips. Wipe each fitting with a clean towel and re-inspect after 60 seconds of held pressure.

Reassembly

1. Confirm all retaining clips are seated and the line does not contact any moving suspension or drivetrain components throughout the full range of motion.
2. Reinstall the wheel and hand-thread 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 battery (positive first, then negative).
6. Close the frunk.
7. Power on the vehicle and exit Jack Mode (the touchscreen will prompt automatically once movement is detected, or manually under Controls > Service).

Verification

• Check the touchscreen for any brake-related alerts (ABS, traction control, brake fluid level warnings). A clear dash is required before driving.
• With the vehicle stationary, press the brake pedal firmly several times — pedal should be firm and consistent, not spongy or sinking.
• Confirm brake fluid reservoir is at MAX line in the frunk.
• Perform a low-speed test in a safe, empty area: gentle braking from 5–10 mph, then progressively firmer stops up to 30 mph. Confirm straight, even braking with no pull.
• Re-inspect the new line and all fittings after the test drive — any sign of weeping requires immediate re-tightening or rework.
• Document the service date. Tesla recommends full brake fluid replacement every 2 years; if the existing fluid is older than that, schedule a complete flush.
• Exit Jack Mode if not already cleared and confirm the air suspension cycles to its normal ride height.

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