Rebuild of the front brake calipers on a 2024 Model Y Long Range AWD, including disassembly of the caliper, replacement of seals/boots/pistons as needed, reassembly with fresh DOT 3 brake fluid, and bleeding. Tesla recommends a brake fluid service every 2 years regardless of mileage — this is a good time to flush the entire system.

Warnings

Tools required

Parts

• Front caliper rebuild kit (piston seals, dust boots, bleeder cap) × 2 — OEM front caliper seal/boot kit for Model Y
• Caliper slide pin boots (if not in rebuild kit) × 2 — OEM slide pin boot set
• Replacement caliper pistons (if pitted/corroded) × 2 — OEM Model Y front caliper piston
• Brake pads (recommended while caliper is off) × 1 — OEM front pad set for Model Y
• Copper crush washers for hydraulic banjo (if applicable) × 4 — OEM crush washer per caliper inlet

Fluids

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

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 (located under the rear seat / front trunk area depending on build — refer to architecture notes). Always disconnect after entering Service Mode via the touchscreen.
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. Enable Service Mode on the touchscreen (Controls → Service) before powering down — this disables regen, Sentry, and pump activation.
7. Loosen front lug nuts while wheels are on the ground.
8. Lift the front of the vehicle using Tesla-approved lift points and pucks; support on jack stands.
9. Remove front wheels and inspect rotors, hoses, and dust shields before starting.
10. Place a catch pan under the caliper area; have shop towels and brake cleaner ready.

Procedure

1. 1

   Cap brake reservoir and prep fluid management
   Open the front trunk, remove the reservoir cap, place a piece of plastic over the opening, and re-cap loosely. This minimizes fluid drip when the line is opened. Confirm reservoir is full — top off with fresh DOT 3 if low.
2. 2

   Disconnect the hydraulic brake line from the caliper
   Using a line wrench, loosen the brake hose fitting at the caliper. Have the catch pan ready. Once loose, plug the hose with a rubber cap or bolt to limit fluid loss. Replace any crush washers on reassembly.
   ⚠Use a flare nut/line wrench only — an open-end wrench will round the fitting.
   Torque spec

   Line Fittings20 Nm (15 lb-ft)
3. 3

   Remove caliper from bracket
   Remove the two caliper guide/slide pin bolts securing the caliper body to the bracket. Slide the caliper off the rotor. If reusing pads temporarily, keep them in order (inner/outer, L/R).
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
4. 4

   Remove caliper bracket (optional but recommended for full rebuild)
   Remove the two front caliper bracket bolts that secure the bracket to the steering knuckle. These are torque-critical and use thread locker — expect high breakaway force.
   ⚠These bolts are critical to vehicle safety. Inspect threads carefully; replace if damaged.
   Torque spec

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

   Extract piston from caliper
   With the caliper off the vehicle and the brake hose disconnected, place a folded shop rag inside the caliper opening and use short bursts of compressed air through the inlet port to pop the piston out. Alternatively use a dedicated piston removal tool. Keep fingers clear.
   ⚠️Compressed air can launch the piston with significant force. Never place fingers between piston and caliper body.
6. 6

   Remove and inspect seals
   Carefully remove the dust boot and the square-cut piston seal from the caliper bore using a plastic or brass pick — do NOT scratch the bore. Inspect the bore for pitting or corrosion. A pitted bore means the caliper must be replaced, not rebuilt.
   ⚠Any scratch in the bore will cause the new seal to leak. Use only non-metallic picks.
7. 7

   Clean all components
   Wash the caliper body, piston, and bracket with brake parts cleaner. Blow dry with compressed air. Inspect the piston — if chrome plating is pitted, scored, or rusty, replace it. Clean slide pins and inspect boots; replace if torn.
8. 8

   Install new piston seal and dust boot
   Lubricate the new square-cut seal with fresh DOT 3 brake fluid (NOT grease) and seat it in the bore groove. Install the new dust boot per the rebuild kit instructions — typically the outer lip seats on the caliper, inner on the piston groove.
9. 9

   Install piston into caliper
   Lubricate the piston with clean DOT 3 fluid and press it squarely into the bore by hand or with a piston compression tool. It should slide smoothly with even resistance. Seat the dust boot fully into both grooves.
   ⚠If the piston cocks sideways, stop and re-align — forcing it will damage the new seal.
10. 10

    Service slide pins
    Clean slide pins, apply fresh silicone brake grease, install new boots if needed, and reinsert into the bracket. Verify smooth travel.
11. 11

    Reinstall caliper bracket
    If removed, clean the bracket bolt threads, apply fresh medium-strength thread locker, and torque to specification. These are critical fasteners.
    Torque spec

    Bracket Bolts102 Nm (75 lb-ft)
12. 12

    Install pads and reinstall caliper
    Install brake pads (new pads recommended) into the bracket with anti-rattle clips properly seated. Apply silicone brake grease to the slide pin bolts and reinstall the caliper, torquing the slide pin bolts to spec.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
13. 13

    Reconnect hydraulic line
    Use a new crush washer (if applicable) and reconnect the brake hose fitting to the caliper. Torque using a line wrench. Inspect the flexible hose for cracks or bulges and replace if questionable.
    Torque spec

    Line Fittings20 Nm (15 lb-ft)
14. 14

    Bleed the brakes
    With reservoir topped off with fresh DOT 3, bleed each caliper. Tesla's recommended sequence and bleeding procedure on Model Y typically requires Service Mode to cycle the iBooster/ABS module — perform a manual bleed at the bleeder screw first, then activate Service Mode brake bleed function on the touchscreen if available. Torque the bleeder screw lightly — do not overtighten.
    ⚠Never let the master cylinder reservoir run dry during bleeding — this will introduce air into the iBooster and require a Tesla-specific bleed procedure.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
15. 15

    Repeat for opposite front caliper
    Perform identical rebuild and bleed on the other front caliper. Brake fluid service interval is 2 years per Tesla — consider flushing both rear calipers as well while the system is open.

Reassembly

1. Confirm all bleeder screws are closed and torqued correctly.
2. Top off reservoir with fresh DOT 3 to the MAX line and reinstall cap.
3. Reinstall front wheels; snug lug nuts by hand.
4. Lower vehicle to the ground.
5. Torque lug nuts to specification in a star pattern.
6. Reconnect the 12V battery and close access panels.
7. Exit Service Mode via touchscreen.

Verification

• With the vehicle still parked, press the brake pedal repeatedly until firm — the pedal should not sink to the floor.
• Check for fluid leaks at every fitting and the caliper body, especially around the new piston seal.
• Inspect dashboard for any ABS, brake, or stability control warnings; clear via Service Mode if needed.
• Drive at very low speed (5–10 mph) in a safe area and apply brakes firmly — confirm even, straight stopping with no pulling.
• Gradually increase test speed; verify no pulsation, dragging, or unusual noise.
• Recheck reservoir level after first drive and top off if needed.
• Log the brake fluid service date — Tesla recommends brake fluid replacement every 2 years regardless of mileage.
• Re-torque lug nuts after 50 miles (Tesla wheel best practice).
• Torque lug nuts in star pattern as specified.

More procedures for this vehicle