Brake Caliper - Rear

Replacement of a rear brake caliper on a 2024 Model Y Long Range AWD. This is a hydraulic-only job (no HV exposure), but the rear caliper integrates the electric parking brake (EPB) actuator, which must be retracted via the touchscreen service mode before removal.

Warnings

Tools required

Parts

• Rear brake caliper assembly (with integrated EPB motor) — manufacturer-specified for 2024 Model Y LR AWD × 1 — OEM Tesla rear caliper assembly — verify left vs. right side
• Copper crush washers for banjo fitting × 2 — OEM-spec copper sealing washers
• DOT 3 brake fluid (sealed container) × 1 — DOT 3 spec

Fluids

• DOT 3 Brake Fluid — 1 qt

Preparation

1. Park on level ground, place in P, and engage the parking brake (it will be released later via the touchscreen).
2. Exit ALL doors with the key fob/phone key 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. On 2024 Model Y, the 12V (Li-ion) battery is accessed under a panel in the front trunk area or beneath rear seating per architecture notes — confirm location before disconnecting.
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 battery: power on the vehicle and use the touchscreen Service menu to place the Electric Parking Brake into 'Brake Service Mode' (or equivalent) to retract the EPB pistons. This step is mandatory — skipping it will prevent caliper removal and may damage the EPB actuator.
7. After EPB is retracted, then perform the 12V disconnect.
8. Loosen rear lug nuts while the vehicle is on the ground.
9. Lift the rear of the vehicle at the manufacturer-specified jacking points using a Tesla-approved puck, support on jack stands, chock the front wheels, and remove the rear wheel.

Procedure

1. 1

   Disconnect EPB actuator harness
   Locate the electric parking brake actuator wiring harness on the back of the rear caliper. Release the connector lock tab and unplug the harness. Inspect the connector for corrosion. Route the harness aside so it cannot be pinched during removal.
   ⚠If the EPB was not first placed in service mode, STOP — do not proceed. Restore 12V power and complete that step first.
2. 2

   Prepare to capture brake fluid
   Position a catch pan beneath the caliper. Have rags ready. Optionally, clamp the flexible brake hose upstream of the caliper with a proper hose clamp tool to minimize fluid loss from the master cylinder reservoir.
3. 3

   Disconnect the brake hose at the caliper
   Using a line wrench where applicable, loosen the banjo bolt (or hydraulic line fitting, depending on configuration) at the caliper inlet. Once loose, remove the bolt and capture the two copper crush washers — these MUST be replaced with new ones on reassembly. Cap or plug the hose to prevent contamination and excessive fluid loss.
   ⚠Do not reuse copper washers — they will leak.
4. 4

   Remove the caliper from the bracket
   Remove the two caliper guide/mounting bolts that secure the caliper body to the caliper bracket. Slide the caliper off the rotor. If pads are being reused, note their orientation.
5. 5

   (If required) Remove the caliper bracket
   If the replacement caliper is supplied as a complete assembly with bracket, remove the two caliper bracket bolts from the rear knuckle/hub carrier. Otherwise, leave the bracket in place. Inspect the bracket for cracks or scoring.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
6. 6

   Transfer pads / inspect rotor
   Transfer brake pads (and any anti-rattle clips) to the new caliper if reusing them, or install new pads as a set. Inspect the rotor for scoring, lip wear, and minimum thickness; replace if out of spec. Clean the rotor face with brake cleaner.
7. 7

   Install new caliper bracket (if removed)
   Apply medium-strength threadlocker to the caliper bracket bolt threads and torque to specification.
   Torque spec

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

   Mount the new caliper
   Position the new caliper over the pads and onto the bracket. Apply medium-strength threadlocker to the caliper mounting bolt threads and torque to specification.
9. 9

   Reconnect the brake hose with NEW copper washers
   Install the brake hose to the caliper using two NEW copper crush washers (one on each side of the banjo fitting). Ensure the hose is not twisted and is routed correctly. Torque the banjo bolt to specification.
   ⚠A twisted or kinked hose will fail prematurely — verify free articulation through full suspension travel.
10. 10

    Reconnect the EPB actuator harness
    Plug the EPB actuator connector into the new caliper until the lock engages. Verify the harness is secured to any retainers and not contacting the rotor or suspension components.
11. 11

    Bleed the rear caliper
    Top up the master cylinder reservoir with fresh DOT 3 brake fluid. Bleed the caliper at the bleeder screw using a vacuum or pressure bleeder until clear, bubble-free fluid flows. Maintain reservoir level throughout. Torque the bleeder screw to specification — do not overtighten.
    ⚠Verify the correct bleeding sequence with the Tesla Service Manual. Tesla typically requires Toolbox-assisted bleeding to cycle the ABS/iBooster — a manual bleed may not fully purge the system.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)

Reassembly

1. Reinstall the rear wheel and snug the lug nuts by hand.
2. Lower the vehicle to the ground.
3. Torque the wheel lug nuts in a star pattern to specification.
4. Reconnect the 12V low-voltage battery.
5. Power on the vehicle. Use the touchscreen Service menu to exit Brake Service Mode and re-calibrate / re-engage the EPB. Cycle the parking brake on/off several times via the touchscreen to verify operation.
6. Top up the brake fluid reservoir to the MAX line with fresh DOT 3.
7. With the vehicle stationary and ignition on, pump the brake pedal until firm before driving.

Verification

• Confirm a firm brake pedal — no sponginess. If spongy, repeat bleed (Tesla often requires a Toolbox-assisted iBooster bleed for full firmness).
• Check for any fluid weeping at the banjo fitting and bleeder screw after a few brake applications.
• Verify no warning messages on the touchscreen related to ABS, EPB, or brake system.
• Test the EPB engagement and release via the touchscreen — listen for the actuator cycling on the serviced caliper.
• Perform a low-speed road test in a safe area: confirm even braking, no pulling, and no grinding. Bed in new pads if pads were replaced, per pad manufacturer instructions.
• Re-check lug nut torque after ~50 miles (Tesla aluminum-faced wheels can settle).
• Note for the owner: Tesla recommends brake fluid service every 2 years regardless of mileage — log this date if the system was opened/bled.

Related trouble codes on this vehicle

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