Complete brake fluid flush on the 2012 Tesla Roadster, replacing all DOT 3 brake fluid in the system. The Roadster uses a Lotus Elise-derived hydraulic brake system with conventional non-ABS-pump bleeding at each caliper.

Warnings

Tools required

Parts

• Bleeder screw dust caps (replace if damaged) × 4 — generic rubber bleeder caps

Fluids

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

Preparation

1. Park on level ground, place the transmission in 1st gear (manual) or 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 before working on the vehicle. On the Roadster, the 12V auxiliary battery is typically located in the front compartment area — refer to the Roadster Owner's Manual for exact location and disconnect procedure.
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 all four wheel lug nuts while the vehicle is on the ground.
7. Raise the vehicle using the manufacturer-specified jacking points (the Roadster has specific reinforced jack pads — do NOT lift on the aluminum extruded chassis rails). Support securely on jack stands.
8. Remove all four wheels.
9. Place absorbent material under each caliper to catch dripping fluid.
10. Identify the brake fluid reservoir on the master cylinder and verify the cap marking specifies DOT 3 (or DOT 4) before proceeding.

Procedure

1. 1

   Inspect system before flushing
   Visually inspect all four flexible brake hoses, hard lines, and caliper bodies for leaks, cracks, or damage. Check pad thickness while the wheels are off. Do not proceed with a flush if a hydraulic component is leaking — repair first.
2. 2

   Evacuate old fluid from reservoir
   Open the master cylinder reservoir cap. Use a clean turkey baster or fluid extractor to remove as much of the old (typically dark) fluid as possible without disturbing the bottom of the reservoir. Wipe the inside of the reservoir with a lint-free towel to remove sediment.
   ⚠Do not let debris fall into the reservoir. Brake fluid will strip paint — protect surrounding bodywork.
3. 3

   Refill reservoir with fresh DOT 3
   Fill the reservoir to the MAX line with fresh DOT 3 brake fluid from a sealed container. This is the new fluid that will be pushed through the system.
4. 4

   Begin bleeding at the furthest caliper
   Following standard practice, begin at the caliper farthest from the master cylinder — typically the passenger-side rear on a left-hand-drive Roadster. Verify the correct sequence in the Tesla Roadster Service Manual, as Roadster routing may differ. Locate the bleeder screw on top of the caliper, remove the dust cap, and fit a clear vinyl hose over the bleeder leading into a catch bottle with a small amount of fresh fluid in the bottom.
   ⚠Bleeder sequence affects how thoroughly air and old fluid are purged. Verify sequence with the service manual.
5. 5

   Flush passenger-side rear caliper
   With an assistant slowly pumping and holding the brake pedal (or using a pressure/vacuum bleeder), crack the bleeder screw open about 1/4 turn. Allow fluid to flow until the discharged fluid runs clear and matches the color of the fresh fluid (typically 100-200 ml per corner). Close the bleeder before the assistant releases the pedal. Top off the reservoir frequently — never let it drop below the MIN line.
   ⚠Bleeder screws on aged calipers can seize. Apply penetrating oil and work gently — a snapped bleeder means caliper replacement.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
6. 6

   Torque rear bleeder and replace cap
   Torque the bleeder screw to specification. Wipe the area clean and reinstall the rubber dust cap.
   Torque spec

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

   Flush driver-side rear caliper
   Move to the driver-side rear caliper and repeat the flushing procedure: clear hose to catch bottle, slow pedal pumps with bleeder cracked open, flush until clean fresh fluid emerges. Top off reservoir constantly.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
8. 8

   Flush passenger-side front caliper
   Move to the passenger-side front caliper and repeat the procedure. Front calipers on the Roadster typically purge faster due to shorter line length.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
9. 9

   Flush driver-side front caliper
   Finish at the driver-side front caliper (closest to master cylinder on LHD). Flush until clean fresh fluid runs clear with no air bubbles. Close and torque the bleeder.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
10. 10

    Final reservoir level and pedal check
    Top off the master cylinder reservoir to the MAX line with fresh DOT 3. Reinstall the reservoir cap and hand-tighten to specification. With the vehicle still on stands, pump the brake pedal multiple times — it should build firm resistance with a high, consistent pedal. A soft or sinking pedal indicates remaining air; repeat the bleed sequence.
    ⚠️Do not move the vehicle until you have a firm brake pedal. A spongy pedal means air remains in the system.
    Torque spec

    Master Cylinder Cap4 Nm (3 lb-ft)

Reassembly

1. Reinstall all four wheels onto the hubs.
2. Hand-thread lug nuts in a star pattern, then snug them while the vehicle is still on stands.
3. Lower the vehicle to the ground.
4. Final-torque all wheel lug nuts in a star pattern to specification.
5. Reconnect the 12V low-voltage battery.
6. Wipe down any fluid residue from calipers, lines, and bodywork with water and a clean towel.

Verification

• With the vehicle off and pedal pumped to firmness, hold steady pressure on the pedal for 30 seconds — it should not slowly sink to the floor (a sinking pedal indicates an internal master cylinder leak).
• Power on the vehicle and confirm no brake-related warnings appear on the instrument cluster.
• Perform a low-speed (5-10 mph) brake test in a clear area before any road use. Confirm the car stops straight with no pull and a firm pedal.
• Road test at progressively higher speeds, checking for pedal feel, pull, and no fluid leaks at each caliper and the master cylinder.
• After the test drive, re-inspect each bleeder and the reservoir for leaks and verify reservoir level is still at MAX.
• Record the service date and mileage. Tesla recommends brake fluid replacement every 2 years regardless of mileage — schedule the next flush accordingly.
• Verify all torque values against the Tesla Roadster Service Manual, as this vehicle uses Lotus-derived chassis hardware that may have model-specific specifications.

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