Brake Hose - Rear

Replace a rear brake hose on the 2012 Tesla Roadster. Note that the Roadster shares its chassis and braking hardware with the Lotus Elise/Exige, so most rear brake hose service follows Lotus procedures rather than later Tesla service documentation.

Warnings

Tools required

Parts

• Rear brake hose (manufacturer-specified for 2012 Roadster — Lotus-platform) × 1 — OEM Tesla Roadster / Lotus rear brake hose — verify by VIN
• Copper sealing washers for banjo fitting × 2 — OEM-spec copper crush washers sized to banjo bolt
• Brake hose retaining clip (if damaged on removal) × 1 — OEM-spec horseshoe / R-clip for chassis bracket

Fluids

• DOT 3 Brake Fluid — 1 qt

Preparation

1. Park on level ground, place transmission in 1st gear (or P on 2-speed early 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 (located in the front trunk/forward compartment area on the Roadster — refer to the service manual for exact location on your VIN).
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. Chock the front wheels, loosen the rear lug nuts while the wheel is on the ground, then raise the rear of the vehicle using manufacturer-specified jacking points and support on jack stands.
7. Remove the rear wheel on the side being serviced.
8. Inspect the master cylinder reservoir fluid level and condition before opening the system; have fresh DOT 3 brake fluid on hand.

Procedure

1. 1

   Inspect routing and identify hose ends
   Trace the rear brake hose from the chassis-mounted hard line fitting down to the caliper banjo connection. Note the routing through any chassis bracket and retaining clip. Photograph the routing for reference during reassembly.
   ℹ️Roadster rear hose routing closely mirrors the Lotus Elise — confirm against your specific VIN configuration.
2. 2

   Pre-loosen the hard line fitting
   Using a flare-nut/line wrench, break loose (do not fully remove) the hard line fitting at the chassis end of the flexible hose. Hold the hex on the hose end with a second wrench to prevent twisting the hose.
   ⚠Always use a line wrench — open-end wrenches will round the soft fitting.
   Torque spec

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

   Remove the caliper banjo bolt
   At the caliper end, position a catch container, then remove the banjo bolt securing the hose to the caliper. Discard both copper washers — they must be replaced. Allow residual fluid to drain into the container.
   ⚠Cap or plug the caliper inlet immediately to prevent contamination.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
4. 4

   Release the hose from the chassis bracket
   Remove the retaining clip (typically a horseshoe / R-clip) securing the hose end into the chassis bracket. Set the clip aside; replace if bent or corroded.
5. 5

   Disconnect hard line and remove hose
   Finish unthreading the hard line fitting from the flexible hose. Once free, remove the hose from the vehicle. Cap the hard line to minimize fluid loss and contamination.
   ⚠Do not bend or kink the steel hard line — replacement requires specialized flaring.
   Torque spec

   Line Fittings20 Nm (15 lb-ft)
6. 6

   Compare new hose to old
   Lay the new hose alongside the old one to verify length, end fitting orientation, and bracket tab position. Roadster/Lotus hoses have a specific clocking — installing the wrong orientation will cause the hose to bind or contact the wheel/suspension at full lock or full droop.
7. 7

   Install new hose at chassis end
   Insert the chassis end of the new hose through the bracket and install the retaining clip fully. Hand-thread the hard line fitting into the hose to avoid cross-threading, then snug with a line wrench. Final torque per spec.
   ⚠Verify hose is not twisted — the bracket tab and clip set the correct clocking.
   Torque spec

   Line Fittings20 Nm (15 lb-ft)

   Brake Hose Bracket10 Nm (7 lb-ft)
8. 8

   Install banjo at caliper with new copper washers
   Place a new copper washer on each side of the banjo fitting. Thread the banjo bolt by hand into the caliper, then torque to specification. Confirm hose has no twist and clears the suspension throughout its travel.
   ⚠Never reuse copper washers — they will weep under pressure.
   Torque spec

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

   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 until clean, air-free fluid flows. Follow the bleed sequence specified in the Tesla Roadster Service Manual (typically furthest-from-master first). Maintain reservoir level throughout.
   ⚠Do not allow the reservoir to run dry or air will enter the master cylinder, requiring a full system bleed.
   Torque spec

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

    Pressure test and inspect for leaks
    With the system bled, have an assistant apply firm pedal pressure (or use a pressure bleeder) and inspect the banjo joint, chassis fitting, and the entire length of the new hose for any seepage. Re-torque only if a leak is detected; do not over-torque.
    Torque spec

    Brake Hose Banjo Bolt25 Nm (18 lb-ft)

    Line Fittings20 Nm (15 lb-ft)

Reassembly

1. Reinstall the rear wheel and hand-thread all lug nuts.
2. Lower the vehicle to the ground.
3. Torque the lug nuts in a star pattern to specification.
4. Reconnect the 12V low-voltage battery.
5. Top off the brake fluid reservoir to the MAX line with fresh DOT 3 fluid and secure the cap.

Verification

• With the vehicle stationary and ignition on, pump the brake pedal — it should build firm pressure within 1-2 strokes and hold without sinking.
• Inspect the banjo fitting and chassis line connection for any sign of weeping after pedal application.
• Perform a low-speed brake test in a safe area: pedal should be firm with no pull to either side and no ABS irregularities.
• At full steering lock and through suspension travel, visually confirm the new hose does not contact the tire, wheel, or any suspension component.
• Record the brake fluid service date — Tesla recommends replacement every 2 years regardless of mileage. If fluid is due, perform a full 4-corner flush now while the system is fresh.
• Recheck rear lug nut torque after the first 50 miles.

More procedures for this vehicle