Replace a front brake hose on a 2024 Model Y Long Range AWD. The hose runs from the hard line at the strut bracket down to the front caliper banjo fitting; this is a standard hydraulic job followed by a brake bleed.

Warnings

Tools required

Parts

• Front brake hose assembly (manufacturer-specified for 2024 Model Y LR AWD) × 1 — Tesla OEM front brake hose — verify left vs right side
• Copper sealing washers for banjo bolt × 2 — Sized to match OEM banjo bolt

Fluids

• DOT 3 Brake Fluid (sealed, fresh 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 key kept well away from the vehicle. Wait at least 2 minutes for HV systems to fully de-energize, even though this is a non-HV job.
3. Disconnect the 12V low-voltage battery. On 2024 Model Y, the 12V battery is located under a cover in the front trunk area / under the rear seat depending on build — refer to architecture notes and service manual to confirm before disconnecting.
4. DO NOT touch, cut, or pierce ANY orange cable. If you encounter an orange cable, an HV component, or are unsure if a system is de-energized, STOP and consult a Tesla-certified technician.
5. Enable Service Mode via the touchscreen prior to 12V disconnect if you wish to suppress vehicle wake events; otherwise ensure Sentry, Summon, and Cabin Overheat Protection are disabled.
6. Loosen the front lug nuts on the affected side while the wheel is still on the ground.
7. Lift the vehicle at the manufacturer-specified front jack point using a Tesla-approved puck. Support on rated jack stands and remove the front wheel.
8. Place a catch pan beneath the caliper area and have rags ready.

Procedure

1. 1

   Inspect the brake hose routing
   Visually trace the hose from the hard-line junction at the strut/frame bracket down to the caliper banjo fitting. Note any retaining clip, bracket, or grommet positions — the replacement hose must be routed identically to avoid contact with the tire, suspension, or steering components at full lock.
2. 2

   Minimize fluid loss (optional)
   If you wish to reduce fluid loss and post-job bleeding, gently clamp the upstream rubber section with rubber-jaw pinch-off pliers. Do NOT clamp on the steel hard line. Skip this step if you intend to perform a full system flush (recommended at the 2-year interval).
   ⚠Never use metal-jaw clamps on a brake hose — they can damage the inner liner and cause failure.
3. 3

   Disconnect hard line from the hose
   Using a flare-nut/line wrench, loosen the hard-line fitting where it threads into the brake hose at the chassis bracket. Have the catch pan positioned. Once disconnected, cap the hard line with a plastic plug to keep contaminants out.
   Torque spec

   Line Fittings20 Nm (15 lb-ft)
4. 4

   Release hose from chassis bracket
   Remove the retaining clip securing the hose fitting to the strut/frame bracket. Set the clip aside on a clean surface — it will be reused unless damaged.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
5. 5

   Remove banjo bolt at caliper
   Position the catch pan under the caliper. Remove the banjo bolt at the caliper inlet and recover the two copper sealing washers (one on each side of the banjo eye). Discard the old washers — they are single-use. Allow residual fluid to drain into the pan.
   ⚠Brake fluid will drip continuously from the open hose end and caliper port. Keep fluid off paint, aluminum suspension components, and ABS sensor wiring.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
6. 6

   Remove the old hose
   Detach the hose from any intermediate routing clips or grommets and remove it from the vehicle. Compare it side-by-side with the new hose to confirm correct length, fitting orientation, and bracket tab position before installation.
7. 7

   Install new banjo end at caliper
   Place a NEW copper washer on each side of the banjo eye (one between bolt head and eye, one between eye and caliper). Thread the banjo bolt by hand to confirm clean engagement, then torque to spec. Ensure the hose's natural orientation does not put the line in a bind.
   ⚠New copper washers are mandatory. Verify final tightening sequence with the Tesla Service Manual.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
8. 8

   Seat hose in chassis bracket and reconnect hard line
   Insert the upper hose fitting through the chassis bracket and reinstall the retaining clip fully. Confirm the hose is not twisted (look at the manufacturer's molded indicator stripe if present). Thread the hard-line fitting into the hose by hand to avoid cross-threading, then torque with a line wrench.
   ⚠Cross-threaded hard-line fittings will leak under pressure. Always start by hand.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)

   Line Fittings20 Nm (15 lb-ft)
9. 9

   Verify hose routing at full steering lock
   With the wheel still off, slowly turn the steering wheel lock-to-lock and cycle the suspension by hand if possible. Confirm the hose does not contact the tire path, wheel liner, control arms, or the CV boot at any point in the travel range.
10. 10

    Bleed the affected brake circuit
    Top off the master cylinder reservoir with fresh DOT 3. Bleed the affected front caliper using the bleeder screw until clean, bubble-free fluid is observed. For best results on a Model Y, follow the Tesla-specified bleed sequence; an ABS-assisted bleed via Service Mode/Toolbox may be required if air entered the ABS module. Torque the bleeder screw when finished.
    ⚠Do not let the reservoir run dry during bleeding — this introduces air into the ABS/iBooster assembly and will require additional service to clear.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
11. 11

    Leak check under pressure
    With the system bled and the reservoir topped to MAX, have an assistant firmly press and hold the brake pedal while you inspect the banjo fitting, hard-line junction, and bleeder screw for any seepage. Wipe each joint dry and re-inspect after several pedal applications.

Reassembly

1. Reinstall the front wheel. Hand-thread all lug nuts before applying any torque.
2. Lower the vehicle until the tire just contacts the ground, then torque the lug nuts in a star pattern to spec.
3. Reconnect the 12V low-voltage battery and reinstall its cover.
4. Top off the brake fluid reservoir to the MAX line with fresh DOT 3 and securely install the cap.
5. Wipe down all hydraulic joints and the surrounding suspension/body to remove residual fluid; flush any spills on paint with water.

Verification

• With the vehicle stationary, press the brake pedal firmly several times — pedal must be firm and not sink under sustained pressure.
• Exit Service Mode (if used) and check the touchscreen for any brake system, ABS, or traction control alerts. Clear any fault codes only after confirming no leaks.
• Perform a low-speed road test in a safe area: verify normal pedal feel, no pull during braking, and that ABS self-test (audible click on first drive) completes without warnings.
• Re-inspect the banjo fitting and hard-line junction after the road test for any weeping.
• Note: Tesla recommends a full brake fluid replacement every 2 years regardless of mileage. Record today's date for the next interval, and consider performing a full flush now if the fluid is at or near that interval.
• Torque lug nuts again after ~50 miles of driving (standard Tesla recommendation after wheel-off service).

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