Replace the rear brake caliper on a 2012 Tesla Roadster. Note: the Roadster shares its braking hardware with the Lotus Elise/Exige platform, so most parts and procedures align with Lotus service information rather than later Tesla models.

Warnings

Tools required

Parts

• Rear brake caliper (Lotus/Roadster-spec) × 1 — OEM-equivalent rear caliper for 2012 Tesla Roadster / Lotus Elise platform — verify side (L/R)
• Copper crush washers for banjo fitting × 2 — OEM-spec copper sealing washers
• Brake pads (if worn or contaminated) × 1 — OEM-spec rear pads — inspect on removal

Fluids

• DOT 3 Brake Fluid — 1 qt

Preparation

1. Park on level ground, place the transmission in gear (or P on automatic units), 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. On the Roadster, the 12V accessory battery is located in the front trunk / forward equipment area — refer to the Roadster Owner's Manual for exact location and disconnect sequence.
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. Loosen the rear wheel lug nuts while the vehicle is on the ground.
7. Safely raise the rear of the vehicle using the manufacturer-specified jacking points and support on jack stands. The Roadster's bonded aluminum chassis is intolerant of incorrect jack placement — verify lift points before raising.
8. Remove the rear wheel.
9. Have a clean container ready to catch brake fluid and shop rags positioned to protect surrounding surfaces.

Procedure

1. 1

   Inspect and document
   Visually inspect the caliper, hose, bracket, rotor, and pads. Photograph the routing of the brake hose and any clips or brackets so you can reinstall the new caliper identically. Note pad orientation and any anti-rattle clips.
2. 2

   Reduce fluid in reservoir / clamp the hose
   Open the brake fluid reservoir cap and use a syringe or turkey baster to remove fluid down to the MIN line to reduce spillage. Optionally, pinch the flexible brake hose with a hose clamp tool to limit fluid loss when the line is opened. Do not clamp braided stainless lines if fitted.
   ⚠Brake fluid is hygroscopic and corrosive. Cap the reservoir as soon as possible.
3. 3

   Disconnect the hydraulic line
   Position a catch pan under the caliper. If the caliper uses a banjo fitting, remove the banjo bolt and discard the two copper washers. If it uses a threaded line fitting, use a line/flare-nut wrench to crack the fitting loose and disconnect. Plug or cap the open line immediately to prevent contamination and minimize fluid loss.
   ⚠Do not allow the hose to twist or kink during disconnection. Protect the line from debris.
4. 4

   Release the parking brake mechanism (if applicable)
   On Roadster rear calipers that integrate a mechanical parking brake mechanism, disconnect the parking brake cable from the caliper lever per the manufacturer-specified procedure. Note the cable routing and any retaining clips.
   ℹ️If you are unsure whether your specific Roadster caliper integrates the parking brake, STOP and refer to the Tesla Roadster Service Manual before forcing any component.
5. 5

   Remove the caliper from the bracket
   Remove the caliper mounting bolts that secure the caliper body to the bracket (or, depending on caliper design, the bolts that secure the entire caliper assembly to the upright). Support the caliper as the last bolt is removed — do not let it hang from the brake hose. Set the caliper on a stand or hang from suspension with a wire/strap.
6. 6

   Remove the caliper bracket (if separating)
   If the caliper bracket is being transferred to a new caliper or replaced, remove the bracket bolts from the rear upright. Clean the mating surfaces with a wire brush and brake cleaner. Inspect threads for damage.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
7. 7

   Transfer pads and hardware
   Transfer brake pads, anti-rattle clips, and any shims to the new caliper in the same orientation as removed, unless replacing pads. Inspect pads for contamination from brake fluid — replace if contaminated. Lubricate slide pins (if present) with the manufacturer-specified caliper grease.
8. 8

   Install the new caliper bracket (if removed)
   Apply medium-strength thread locker to the bracket bolt threads. Install the bracket onto the rear upright and torque the fasteners to specification in a cross pattern.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
9. 9

   Install the new caliper
   Position the new caliper over the rotor and pads. Apply medium-strength thread locker to the caliper mounting bolts. Install bolts hand-tight, then torque to specification.
   ⚠Confirm the rotor spins freely after caliper installation, with only light pad-to-rotor contact.
10. 10

    Reconnect the hydraulic line
    Reconnect the brake line. For banjo fittings, install NEW copper washers on each side of the banjo eyelet and torque the banjo bolt to specification. For threaded fittings, start the threads by hand to avoid cross-threading and torque using a line wrench. Remove the hose pinch tool if used.
    ⚠️Reusing copper crush washers can cause a brake fluid leak and total loss of braking. Always use new washers.
11. 11

    Reconnect parking brake (if applicable)
    Reattach the parking brake cable to the caliper lever and any retaining clips. Verify free movement of the lever and that the cable is routed without binding.
12. 12

    Bleed the rear brake circuit
    Refill the master cylinder reservoir with fresh DOT 3 brake fluid. Bleed the rear caliper using the bleeder screw. Follow the manufacturer-specified bleed sequence — typically furthest-from-master-cylinder first, but verify in the Roadster Service Manual. Continue until clear, bubble-free fluid emerges. Torque the bleeder screw to specification — do NOT overtighten.
    ⚠Keep the reservoir topped up throughout bleeding. Allowing it to run dry will introduce air into the master cylinder and require a full system bleed.
    ℹ️Verify the correct bleed sequence with the Tesla Roadster Service Manual — sequence is critical to fully purging air.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)

Reassembly

1. Top off the master cylinder reservoir to the MAX line with fresh DOT 3 brake fluid and reinstall the cap.
2. Reinstall the rear wheel and snug the lug nuts by hand.
3. Lower the vehicle to the ground.
4. Torque the wheel lug nuts in a star pattern to specification.
5. Reconnect the 12V low-voltage battery.
6. Wipe down the caliper, hose connections, and surrounding area with brake cleaner to remove any residual fluid — this also helps spot leaks during the test.

Verification

• With the vehicle stationary and engine/system off, pump the brake pedal until firm. Pedal should not sink to the floor and should feel consistent with pre-repair feel.
• Inspect the banjo/line fitting and bleeder for any signs of leakage with the pedal held under pressure.
• If the parking brake was disconnected, verify it engages and releases properly and that the rear wheel locks when applied.
• Power the vehicle on and confirm no brake-related warnings appear on the instrument cluster.
• Perform a low-speed brake test in a safe area (under 10 mph), gradually increasing speed only after confirming firm pedal and straight braking.
• Recheck fluid level after the test drive and inspect the caliper area for leaks.
• Note: Tesla recommends a complete brake fluid flush every 2 years regardless of mileage. Record this service date for the next interval.
• If anything feels abnormal — soft pedal, pulling, dragging, or warning lights — STOP driving and reinspect or consult a qualified Tesla Roadster technician.

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