Rebuild the rear brake calipers on a 2024 Model X Plaid, including caliper removal, piston extraction, seal replacement, and reassembly. The Model X Plaid uses electric parking brakes integrated into the rear calipers, requiring service mode activation before disassembly.

Warnings

Tools required

Parts

• Rear caliper rebuild kit (piston seals, dust boots, slide pin boots, bleeder cap) × 2 — Manufacturer-specified rear caliper seal kit for Model X (2022+ refresh)
• Caliper slide pins (if worn or pitted) × 1 — OEM-spec slide pin set
• Silicone brake caliper grease (for slide pins and boots) × 1 — Generic silicone brake grease
• Brake cleaner aerosol × 2 — Non-chlorinated brake parts cleaner

Fluids

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

Preparation

1. Park on level ground, place in P, and engage the parking brake via the touchscreen.
2. Exit ALL doors with the key fob/phone 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 (Model X frunk battery, similar position to Model S). Follow the documented frunk-access procedure — do not pry the frunk open if the 12V is dead without using the external jump terminals.
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 lifting: enter Service Mode > Chassis > Brakes and place rear EPB calipers in 'Service Mode' (piston retract / open) so the EPB motor backs off. Then exit normally.
7. Activate Jack Mode via touchscreen (Controls > Service > Jack Mode) to disable air suspension self-leveling.
8. Be aware of falcon doors overhead — keep them closed during the job and ensure no one triggers them from inside the cabin.
9. Loosen rear lug nuts while wheels are on the ground, then raise the rear of the vehicle on manufacturer-approved lift points and support with rated jack stands.

Procedure

1. 1

   Remove rear wheels
   Fully remove the rear lug nuts and pull the wheels. Set them aside on their faces to avoid scratching the finish. Inspect rotors and pads for wear before proceeding — if rotors are below spec, plan to replace them during reassembly.
2. 2

   Disconnect EPB actuator wiring
   Locate the electric parking brake motor connector at the rear of each caliper. Confirm the EPB has been retracted via Service Mode. Release the connector lock and unplug the harness. Tuck the harness clear of the suspension travel path.
   ⚠If the connector resists release, do not pry — verify Service Mode/retract was completed and 12V was disconnected after retract.
3. 3

   Clamp the brake hose and disconnect the line
   Apply a hose clamp to the rubber section of the brake line to minimize fluid loss. Place a catch pan under the caliper. Loosen the banjo bolt or fitting at the caliper inlet and disconnect the brake line. Cap or plug the line. Discard sealing washers if banjo-style.
4. 4

   Remove caliper from bracket
   Remove the two caliper slide pin bolts that secure the caliper body to the caliper bracket. Lift the caliper off the rotor and place it on a clean bench. Remove the brake pads and inspect retaining clips/anti-rattle springs.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
5. 5

   Remove caliper bracket (optional, for full clean/inspect)
   If the bracket will be cleaned and inspected, remove the two bracket bolts securing it to the rear knuckle. Note bolt orientation. Inspect threads in the knuckle for damage.
   Torque spec

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

   Extract piston from caliper body
   With the caliper off the vehicle and any residual fluid drained, use low-pressure compressed air directed into the brake fluid inlet port to pop the piston out. Place a wooden block in the caliper opening to prevent piston damage. If air will not move the piston (common on EPB calipers with the actuator still attached), separate the EPB motor housing from the caliper per the manufacturer-specified procedure first, retaining all shims and the threaded spindle.
   ⚠Keep fingers clear of the piston bore — pistons can eject with significant force.
7. 7

   Remove old seals and clean bore
   Using a non-metallic pick, carefully extract the dust boot and the inner square-cut piston seal from the caliper bore. Do not gouge the bore or seal groove. Clean the bore, piston, and grooves thoroughly with fresh brake fluid or brake cleaner. Inspect the bore for pitting, scoring, or corrosion — if present, the caliper must be replaced rather than rebuilt.
8. 8

   Inspect and clean slide pins and boots
   Pull the slide pins from the caliper bracket. Inspect for pitting, corrosion, and straightness. Replace boots if torn. Clean pins and re-lubricate with silicone brake grease before reinstalling into the bracket.
9. 9

   Install new seals and piston
   Lubricate the new square-cut 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 in the caliper first, then over the piston; others install on the piston first). Lubricate the piston OD with brake fluid and press it squarely into the bore until fully seated. Ensure the dust boot lip is properly captured in both the caliper groove and the piston groove.
   ⚠A cocked piston will tear the new seal. Press straight in — if resistance is uneven, back out and realign.
10. 10

    Reinstall EPB actuator (if separated)
    If the EPB motor was separated for piston extraction, refit any shims/spacers in original orientation, mate the actuator to the caliper, and torque the actuator fasteners to OEM specification — refer to Tesla Service Manual. Reconnect the EPB harness only after the caliper is bolted back to the vehicle and 12V is reconnected.
11. 11

    Reinstall caliper bracket and caliper
    If removed, reinstall the caliper bracket to the knuckle. Apply medium-strength threadlocker to bracket bolt threads if specified by the service manual. Install brake pads with anti-rattle hardware. Slide the caliper over the rotor and pads, and install the slide pin bolts with silicone brake grease applied to the slide pin shafts (not the threads).
    Torque spec

    Bracket Bolts102 Nm (75 lb-ft)

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
12. 12

    Reconnect brake line
    Reconnect the brake line to the caliper using new sealing washers if banjo-style. Torque the bleeder screw cap and brake line fitting to OEM specification — refer to Tesla Service Manual. Remove the hose clamp.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
13. 13

    Bleed the rear brake circuit
    Top off the master cylinder reservoir with fresh DOT 3 brake fluid. Bleed the rebuilt rear caliper(s) using a pressure bleeder or two-person pedal method until clean, bubble-free fluid emerges. Torque the bleeder screw between bleeds. Maintain reservoir level throughout — do not allow it to run dry. Repeat on the opposite rear caliper if both were rebuilt.
    ⚠Model X uses an iBooster-style electronic brake assist. A full system bleed including ABS module activation may require Tesla service tooling — at minimum, perform a road-test bleed cycle after the manual bleed and re-bleed if pedal feel is soft.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
14. 14

    Reinstall wheels
    Mount the rear wheels and hand-thread all lug nuts. Lower the vehicle until the tires just contact the ground, then torque the lug nuts in a star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Reconnect the 12V battery in the frunk and close the frunk.
2. Reconnect the EPB harness connectors at each rear caliper if not already done.
3. Power on the vehicle and exit Jack Mode.
4. Enter Service Mode > Chassis > Brakes and run the EPB calibration / exit-service-mode routine to re-clamp the parking brake pistons against the new pads.
5. Cycle the brake pedal 10-15 times with the vehicle stationary to take up piston clearance before driving.
6. Verify firm pedal feel before any movement. If pedal goes to the floor, re-bleed.
7. Top off the brake fluid reservoir to the MAX line with fresh DOT 3.

Verification

• Confirm no brake fluid leaks at the caliper inlet, bleeder, and piston dust boot after several pedal applications.
• With the vehicle in Service Mode, command the EPB apply/release and confirm both rear actuators cycle audibly and without fault.
• Clear any chassis/brake DTCs in Service Mode and re-scan to confirm no codes return.
• Perform a low-speed (10-15 mph) brake test in a safe area, then a moderate stop from 30 mph. Pedal should be firm and the vehicle should track straight with no pull.
• Recheck wheel lug nut torque after the first 50 miles in a star pattern.
• Tesla recommends brake fluid replacement every 2 years regardless of mileage — log this service date and plan the next flush accordingly.
• After driving, recheck the master cylinder reservoir level and top off if needed.

More procedures for this vehicle