Replace a single front brake rotor on a 2024 Model X Plaid. The Plaid uses high-performance front calipers; with proper tools this is a straightforward job, but caliper weight and AWD-specific drag torque require care.

Warnings

Tools required

Parts

• Front brake rotor, OEM-spec for Model X Plaid × 1 — Tesla Model X Plaid front rotor — confirm size/vented spec via VIN at parts counter
• Rotor set screw (if damaged on removal) × 1 — OEM hub-to-rotor retaining screw

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 in the frunk (lift frunk liner, remove battery cover, disconnect negative terminal first). See architecture notes for location.
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 > Jack Mode) to lock air suspension at current ride height.
7. Loosen (do not remove) the front wheel lug nuts while the vehicle is on the ground.
8. Lift the front of the vehicle at the Tesla-approved front jack points using rubber pucks. Support on jack stands rated for vehicle weight.
9. Remove the front wheel and set aside on its face to protect the finish.

Procedure

1. 1

   Inspect and document
   Photograph the caliper, bracket, rotor, and brake line routing before disassembly. Note the orientation of any shims or anti-rattle clips. Inspect the flexible brake hose for cracks while you're in there.
2. 2

   Remove caliper from bracket
   Depending on caliper design, either remove the two caliper slide pin bolts (floating caliper) or the two caliper bolts attaching the caliper body (fixed/monoblock). The Plaid front uses a high-performance fixed caliper — remove the caliper bolts. Do not disconnect the brake hose.
   ⚠Front caliper is heavy. Have a hanger ready before the second bolt comes out.
   Torque spec

   Caliper Bolts88 Nm (65 lb-ft)

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Support the caliper
   Hang the caliper from a suspension component using a caliper hanger or bungee. The brake hose must not bear any caliper weight and must not be kinked or twisted.
4. 4

   Remove caliper bracket (if equipped separately)
   If the caliper used a separate bracket, remove the two front caliper bracket bolts. On Plaid fixed-caliper designs the caliper itself mounts directly to the knuckle and there is no separate bracket — skip if not applicable.
   Torque spec

   Caliper Bracket Bolts102 Nm (75 lb-ft)
5. 5

   Remove rotor set screw
   Remove the small Torx/hex set screw that retains the rotor to the hub. These are often seized — apply penetrating oil and use a properly sized bit to avoid stripping. Replace the screw if the head is damaged.
   ⚠Stripping this screw turns a 0.8 hr job into a 3 hr job. Use a hand impact driver if seized.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
6. 6

   Remove the rotor
   Pull the rotor straight off the hub. If corroded to the hub, thread two appropriately sized bolts into the threaded jacking holes in the rotor hat (if present) and tighten evenly to push the rotor off. Do NOT strike the rotor near the hub bearing or wheel speed sensor with a steel hammer — use a dead-blow if needed and only on the rotor hat.
   ⚠Wheel speed sensor and ABS tone ring are integrated into the hub assembly — do not pry against them.
7. 7

   Clean the hub face
   Wire-brush the hub mating surface until clean and flat. Any rust scale here causes lateral runout and brake judder. A very thin film of anti-seize on the hub face (NOT on the friction surface) is acceptable to prevent future seizure.
8. 8

   Prep the new rotor
   Wipe the new rotor's friction surfaces thoroughly with brake cleaner to remove shipping preservative oil. Verify the rotor matches the original in diameter, thickness, vane direction (if directional), and hat depth.
   ℹ️Plaid front rotors may be directional — confirm rotation arrow points in forward wheel-rotation direction.
9. 9

   Install new rotor
   Slide the new rotor onto the hub, aligning the set-screw hole. Install and torque the rotor set screw.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
10. 10

    Reinstall caliper bracket (if removed)
    If a separate bracket was removed, apply medium-strength threadlocker to the bracket bolts and torque to the manufacturer-specified front caliper bracket value. Verify bolt sequence with the Tesla Service Manual.
    Torque spec

    Caliper Bracket Bolts102 Nm (75 lb-ft)
11. 11

    Inspect and reinstall pads
    Inspect pads for even wear, minimum thickness, and cracking. If pads are below spec or contaminated, replace as a set. Reinstall pads with any anti-rattle hardware in original orientation.
12. 12

    Reinstall caliper
    Position the caliper over the new rotor and pads. Apply medium-strength threadlocker to caliper bolts (or silicone brake grease to slide pins if applicable) and torque to spec. Verify bolt tightening sequence with the Tesla Service Manual.
    Torque spec

    Caliper Bolts88 Nm (65 lb-ft)

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)

Reassembly

1. Reinstall the wheel; hand-thread all lug nuts before applying any torque.
2. Lower the vehicle until the tire just contacts the ground, then torque the wheel lug nuts in a star pattern.
3. Lower the vehicle fully and remove jack stands.
4. Reconnect the 12V battery (positive first, then negative). Reinstall battery cover and frunk liner.
5. With the vehicle on the ground and the brake pedal NOT pressed, exit Jack Mode via the touchscreen (it may also clear automatically once driven).
6. Before starting/driving: pump the brake pedal firmly multiple times until it becomes firm. The pedal will be soft on the first stroke because the pads are retracted from the rotor.
7. Check brake fluid level in the reservoir; top up with DOT 3 brake fluid only if low.
8. Inspect for any tools, rags, or hardware left in the wheel well.

Verification

• With vehicle stationary and firm pedal confirmed: roll slowly in a safe area and apply brakes lightly. Listen for grinding, scraping, or pulling.
• Check the touchscreen for any ABS, traction control, or brake warning indicators. The Plaid will throw a chassis warning if a wheel speed sensor was disturbed.
• Perform a proper bed-in procedure on the new rotor: a series of moderate stops from ~60 to ~10 mph, followed by gentle driving to cool — follow rotor manufacturer's specific procedure.
• After the first 50-100 miles, re-check wheel lug torque (Tesla recommends a re-torque after wheel service).
• Note: Tesla recommends a brake fluid service every 2 years regardless of mileage — log the date and consider performing if overdue.
• After driving, verify air suspension self-levels correctly and no ride-height fault is shown on the touchscreen.

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