Replacement of a front brake caliper on a 2024 Model Y Long Range AWD. Standard hydraulic brake service — no HV systems involved, but follow Tesla 12V isolation procedure to prevent ABS/regen module faults.

Warnings

Tools required

Parts

• Front brake caliper assembly (manufacturer-specified for 2024 Model Y LR AWD — left or right specific) × 1 — OEM Tesla front caliper — verify side and trim
• Copper crush washers for banjo fitting × 2 — Match caliper banjo bolt size
• Brake pads (recommended if not recently replaced) × 1 — OEM front pad set for Model Y LR

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. Disconnect the 12V low-voltage battery (located under/behind the rear seat or in the front trunk area depending on build — verify on this 2024 Model Y). Insulate the negative terminal.
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. Disable Sentry Mode and Cabin Overheat Protection in the touchscreen before disconnecting 12V to avoid alarm triggers.
7. Place wheel chocks at the rear wheels.
8. Loosen front lug nuts a quarter turn before raising the vehicle.
9. Raise the front of the vehicle at the manufacturer-specified jacking points using a jack pad and support on rated jack stands.
10. Remove the front wheel on the affected side.

Procedure

1. 1

   Inspect and prepare the corner
   Visually inspect the caliper, hose, bracket, rotor, and pads. Note routing of the brake hose and any clips/retainers. Photograph for reference. Confirm you have the correct left/right caliper for replacement.
2. 2

   Reduce hydraulic pressure at the caliper
   Place a catch pan beneath the caliper. Optionally clamp the flexible brake hose with a hose pinch-off tool to minimize fluid loss from the master cylinder reservoir. Crack the banjo bolt or hard-line fitting slightly to release residual pressure, then re-snug temporarily.
   ⚠Do not over-clamp the rubber brake hose — use a tool designed for brake hoses to avoid internal liner damage.
3. 3

   Disconnect the brake hydraulic line
   Position the catch pan. Fully unthread the banjo bolt (or hard-line fitting, depending on caliper configuration) from the caliper. Discard the copper crush washers — they are single-use. Cap or bag the hose end to keep contaminants out and minimize drip.
   ⚠Brake fluid will drip — protect suspension components, the aluminum hub, and any painted surfaces.
4. 4

   Remove the caliper from its bracket
   Remove the two caliper guide/mounting bolts securing the caliper body to the bracket. Support the caliper as the second bolt is removed so it does not fall.
5. 5

   (Optional) Remove the caliper bracket
   If the replacement is supplied as a bracket-and-caliper assembly, remove the two large caliper bracket bolts from the steering knuckle. These are high-torque fasteners — use a long breaker bar. Discard old threadlocker residue from the knuckle threads with a thread chaser if reusing.
   ⚠The Model Y front knuckle is aluminum — do not strike with a steel hammer. Use a dead-blow or brass drift if persuasion is needed.
   Torque spec

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

   Transfer pads and hardware
   Move the brake pads (if reusing) and any anti-rattle clips/shims from the old caliper/bracket to the new unit. Inspect pads for wear; replace if near wear limit. Clean the bracket abutments and apply a thin film of high-temp brake lubricant to pad contact points (not the friction surface).
7. 7

   Install the new caliper bracket (if removed)
   Apply medium-strength threadlocker to the caliper bracket bolts. Hand-thread both bolts, then torque to specification.
   Torque spec

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

   Mount the new caliper
   Position the caliper over the pads and bracket. Apply medium-strength threadlocker to the caliper mounting bolts (unless pre-applied on new fasteners). Hand-start both bolts, then torque to specification.
9. 9

   Reconnect the brake hose with new washers
   Install NEW copper crush washers on both sides of the banjo fitting. Thread the banjo bolt by hand to avoid cross-threading, ensure the hose is oriented per the original routing (no twist, no contact with suspension), then torque to specification.
   ⚠Reusing copper washers will cause a slow leak and potential brake failure.
10. 10

    Bleed the caliper
    Top off the master cylinder reservoir with fresh DOT 3 brake fluid. Remove any hose pinch-off tool. Bleed the caliper at the bleeder screw using a vacuum bleeder or two-person pedal method until clear, bubble-free fluid flows. Tesla recommends following the service-manual sequence — verify before bleeding multiple corners.
    ⚠Do not let the master cylinder reservoir run dry during bleeding — this will introduce air into the ABS/iBooster module which may require Tesla Toolbox to fully purge.
    ℹ️Since the system is open, this is an ideal time to perform the 2-year brake fluid service.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Final leak and pedal check
    With the bleeder closed and torqued, have an assistant apply firm pedal pressure while you inspect the banjo fitting and bleeder for any seepage. Pedal should be firm; if spongy, repeat bleed.

Reassembly

1. Top off the brake fluid reservoir to the MAX line with fresh DOT 3 fluid.
2. Reinstall the front wheel. Hand-thread all lug nuts to avoid cross-threading the aluminum hub studs.
3. Lower the vehicle to the ground.
4. Torque lug nuts in a star pattern to specification.
5. Reconnect the 12V battery negative terminal.
6. Re-enable Sentry Mode / Cabin Overheat Protection if previously disabled.
7. Power on the vehicle and allow it to complete its self-checks. Expect transient ABS, traction, and Autopilot warnings — these typically clear after a short drive cycle and steering calibration.

Verification

• With the vehicle ON and brake-by-wire pressurized, re-inspect the banjo fitting and bleeder for leaks.
• Pump the pedal several times — it should be firm and consistent. A sinking pedal indicates a leak or trapped air.
• Check the touchscreen for any active brake, ABS, or stability control alerts. Drive slowly in a safe area and confirm normal braking before normal use.
• Perform a low-speed bedding-in procedure if pads were replaced (per pad manufacturer instructions).
• After the first drive, re-check the wheel lug torque and inspect the banjo fitting once more for weeping.
• Note: Tesla recommends brake fluid replacement every 2 years — log the service date in your maintenance records.
• Note: Tesla recommends front tire rotation every 6,250 miles on Model Y — schedule accordingly since the wheel is already off.

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