Replacement of a rear brake hose on a 2024 Model Y Performance AWD. This restores the hydraulic line between the chassis hard line and the rear caliper, and requires a full brake bleed afterward.

Warnings

Tools required

Parts

• Rear brake hose (manufacturer-specified for Model Y Performance) × 1 — Tesla OEM rear brake hose — verify side (LH/RH)
• Copper sealing washers for banjo fitting × 2 — New crush washers — banjo bolt size
• Brake hose bracket retaining clip (if damaged on removal) × 1 — OEM U-clip / horseshoe clip

Fluids

• DOT 3 Brake Fluid — 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 behind/under the rear seat area on Model Y — refer to the in-vehicle service mode disconnect procedure if available).
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. Place the vehicle in Transport Mode / Jack Mode via the touchscreen before lifting (this disables auto-leveling and prevents drive system wake events).
7. Loosen the rear lug nuts while the wheel is still on the ground.
8. Lift the rear of the vehicle at the OEM jack points using a Tesla-approved puck and support with jack stands.
9. Remove the rear wheel on the side being serviced.
10. Inspect the new brake hose against the old one for correct length, routing, and fitting orientation before installation.

Procedure

1. 1

   Cap off the master cylinder reservoir to limit fluid loss
   Open the brake fluid reservoir cap, place a piece of plastic over the opening, and reseal. This creates a partial vacuum that slows fluid drainage from the open hose during replacement. Do not let fluid level fall below MIN.
2. 2

   Clean fittings before disassembly
   Thoroughly clean the banjo fitting at the caliper and the hard-line union at the chassis end of the hose with brake parts cleaner. Any debris entering the system will damage ABS/iBooster components.
3. 3

   Disconnect the hard line at the chassis end
   Using a flare-nut wrench, hold the hose hex with one wrench and break the hard-line tube nut loose with the other. Back the tube nut off fully. Cap the hard line immediately to prevent contamination and minimize drip.
   ⚠Use a flare-nut wrench, not an open-end. Rounding the tube nut will require replacing the hard line.
4. 4

   Release the hose from its chassis bracket
   Remove the retaining horseshoe clip securing the hose fitting to the chassis bracket. Pull the hose end free of the bracket. Inspect the clip; replace if distorted.
5. 5

   Free the hose from any intermediate routing bracket
   If the hose passes through an intermediate bracket on the suspension/subframe, remove the small fastener securing it. Note routing — the new hose must follow the same path to avoid contact with the tire, suspension arms, or HV pack underside.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
6. 6

   Remove the banjo bolt at the caliper
   Place a catch container under the caliper. Remove the banjo bolt at the rear caliper inlet and discard both copper washers. Allow residual fluid to drain. Cap the caliper port to prevent contamination.
   ⚠Brake fluid is corrosive to paint and aluminum — wipe any drips off the caliper, suspension, and underbody immediately.
7. 7

   Remove the old hose
   Withdraw the old hose, noting any heat-shield routing or clip orientations. Compare side-by-side with the new hose to confirm correct length and end fittings.
8. 8

   Install the new hose at the caliper (banjo end)
   Place a NEW copper washer on each side of the banjo fitting (one between bolt head and fitting, one between fitting and caliper). Thread the banjo bolt by hand to avoid cross-threading, then torque to specification. Position the hose so it does not twist as it routes upward.
   ⚠Always use new copper washers. The banjo fitting orientation must match the original — incorrect clocking can cause tire or suspension contact at full droop or full lock.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
9. 9

   Route the hose and seat it in the chassis bracket
   Route the new hose along the original path. Seat the upper fitting into the chassis bracket and install the retaining horseshoe clip until fully seated. Verify the hose is not twisted by checking that any molded-in alignment marks or flat surfaces are oriented correctly.
10. 10

    Reconnect the hard line
    Start the hard-line tube nut by hand into the hose fitting to avoid cross-threading. Tighten with a flare-nut wrench to OEM specification — refer to Tesla Service Manual for the hard-line tube nut value.
11. 11

    Secure any intermediate routing bracket fastener
    Reinstall any intermediate hose bracket fastener and torque to specification.
    Torque spec

    Brake Hose Bracket10 Nm (7 lb-ft)
12. 12

    Cycle suspension and verify clearance
    With the vehicle still raised, cycle the suspension by hand (where possible) and turn the steering if applicable. Confirm the new hose has clearance from the tire, suspension links, subframe, and underbody at all positions. There must be no contact with HV pack underside or pack fasteners.
    ⚠️If the hose contacts any orange cable or HV pack component, STOP. Re-route or consult a Tesla-certified technician.
13. 13

    Bleed the rear brake circuit
    Top off the master cylinder reservoir with fresh DOT 3 brake fluid. Bleed the affected rear caliper using the bleeder screw — pump/vacuum until clean, bubble-free fluid is observed. Maintain reservoir level above MIN throughout. Torque the bleeder when finished.
    ℹ️A full ABS/iBooster bleed via Tesla service software may be required if the pedal remains spongy after manual bleeding. This is a known limitation of manual bleeding on Tesla iBooster systems.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
14. 14

    Pressure-check for leaks
    With the system bled, have an assistant firmly apply and hold the brake pedal while you inspect both the banjo fitting and the hard-line union for any seepage. Repeat after several pedal applications.

Reassembly

1. Top off the brake fluid reservoir to the MAX line with fresh DOT 3.
2. Reinstall the rear wheel; snug lug nuts in a star pattern by hand.
3. Lower the vehicle to the ground.
4. Final-torque the wheel lug nuts in a star pattern.
5. Reconnect the 12V low-voltage battery.
6. Exit Jack Mode / Transport Mode via the touchscreen.
7. Wipe down all areas where brake fluid may have contacted paint or aluminum.

Verification

• With the vehicle off, press the brake pedal multiple times — pedal should be firm and consistent, not spongy or sinking.
• Power up the vehicle and check the touchscreen for any brake system, ABS, or traction control alerts.
• At low speed in a clear area, confirm the brake pedal feel is normal and the vehicle decelerates straight without pulling.
• Re-inspect the banjo fitting and hard-line union after a short test drive for any weeping fluid.
• Recheck brake fluid level after the test drive and top off if needed.
• Record the brake fluid service date — Tesla recommends brake fluid replacement every 2 years regardless of mileage; a hose replacement is a natural opportunity to reset that interval if a complete fluid flush was performed.
• Note tire condition while the wheel is off — Model Y Performance wears rear tires quickly; Tesla recommends rotation every 6,250 miles.

More procedures for this vehicle