Replace front brake pads and rotors on a 2012 Tesla Roadster. Note that the Roadster shares its chassis and front brake hardware with the Lotus Elise/Exige platform — components are largely Lotus-sourced, not Tesla-specific.

Warnings

Tools required

Parts

• Front brake pads (Lotus-platform spec for Tesla Roadster) × 1 — OEM-equivalent front pad set — verify with Roadster service documentation
• Front brake rotors × 2 — OEM-equivalent front rotors — verify with Roadster service documentation
• Caliper bolt threadlocker × 1 — Medium-strength blue threadlocker

Fluids

• DOT 3 Brake Fluid (top-off only if needed)

Preparation

1. Park on level ground, place transmission in gear (or P if applicable), 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 near the vehicle. Refer to the Roadster Owner's/Service Manual for the 12V battery location on this model.
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 front wheel lug nuts while the car is still on the ground.
7. Lift the front of the vehicle at the manufacturer-specified jacking points and support securely on jack stands. Never rely on a jack alone.
8. Remove both front wheels and set them aside.
9. Inspect the brake fluid reservoir level — pushing pistons back will displace fluid upward. Remove some fluid with a clean syringe if the reservoir is near full to avoid overflow.

Procedure

1. 1

   Inspect existing brake hardware
   Visually inspect the front calipers, brake hoses, and rotor surfaces. Note the orientation of pads, anti-rattle clips, and any shims so they can be reinstalled correctly. Photograph the assembly before disassembly.
2. 2

   Compress the caliper pistons
   Using a piston compression tool or C-clamp against an old pad, slowly press the caliper pistons back into their bores to make room for the new, thicker pads. Monitor the brake fluid reservoir during this step to prevent overflow.
   ⚠Do not pry directly against a piston face — use a pad or block to distribute force and avoid damaging the piston seal.
3. 3

   Remove the caliper from the bracket
   Remove the caliper mounting fasteners (slide bolts or caliper bolts depending on configuration). Lift the caliper off the rotor and support it with a wire hook or bungee from the suspension — DO NOT let it hang by the brake hose. If the Roadster uses fixed (opposed-piston) calipers without slide pins, instead remove the bracket-to-knuckle bolts as a unit.
   ⚠Hanging the caliper by the brake hose can damage the hose internally and cause failure.
   Torque spec

   Caliper Slide Bolts34 Nm (25 lb-ft)

   Caliper Bolts88 Nm (65 lb-ft)
4. 4

   Remove the brake pads
   Slide the old pads out of the caliper or bracket. Note the position of any shims, wear sensors (if equipped), and anti-rattle springs. Set hardware aside for cleaning or replacement.
5. 5

   Remove the caliper bracket (if separate)
   If the rotor is retained behind a separate caliper carrier bracket, remove the bracket-to-knuckle bolts to access the rotor. Torque to OEM specification on reinstallation — refer to the Tesla Roadster Service Manual to confirm which torque value applies to your specific bracket configuration.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
6. 6

   Remove the old rotor
   Remove any rotor retaining screws or clips if present. Pull the rotor straight off the hub. If the rotor is seized to the hub due to corrosion, apply penetrating oil at the hub center and use a soft mallet on the rotor hat (NEVER on the hub or chassis).
   ⚠Aluminum upright/knuckle on the Roadster — avoid striking suspension components directly.
7. 7

   Clean hub mating surface
   Wire-brush the hub face to remove rust and debris. A clean, flat mating surface is essential to prevent rotor runout. A very thin film of anti-seize on the hub center (NOT on the friction surface or studs) helps prevent future seizing.
8. 8

   Install the new rotor
   Wipe the new rotor's friction surfaces clean with brake cleaner to remove any shipping oil. Install the rotor onto the hub, reinstalling any retaining screw if originally fitted.
9. 9

   Reinstall caliper bracket (if removed)
   Apply medium-strength threadlocker to the bracket bolts. Install the bracket and torque the fasteners to specification. Verify torque value against the Tesla Roadster Service Manual before applying — multiple bracket torque specs exist for this platform.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
10. 10

    Install the new pads
    Install any anti-rattle clips/shims, then seat the new pads into the bracket or caliper in the same orientation as the originals. Apply a thin film of silicone brake grease to pad backing plate contact points and slide pin surfaces (if equipped) — never on the friction surface.
11. 11

    Reinstall the caliper
    Lower the caliper over the new pads and rotor. Apply medium-strength threadlocker to caliper fasteners as specified, and torque to the appropriate value. Confirm the correct torque spec for your specific caliper configuration in the service manual.
    ⚠Verify which fastener type (through-bolts vs. slide pins) your Roadster front caliper actually uses before applying torque — early and late Roadster brake hardware may differ.
    Torque spec

    Caliper Bolts88 Nm (65 lb-ft)

    Caliper Slide Bolts34 Nm (25 lb-ft)
12. 12

    Repeat for the opposite front wheel
    Repeat steps 1-11 on the other side of the vehicle.

Reassembly

1. Verify the brake fluid reservoir is at the correct level; top off with fresh DOT 3 brake fluid if needed.
2. Reinstall both front wheels. Hand-thread all lug nuts, then snug them in a star pattern.
3. Lower the vehicle to the ground.
4. Final-torque the wheel lug nuts in a star pattern to specification.
5. Reconnect the 12V low-voltage battery.
6. Before driving, with the vehicle stationary and the wheels unable to move, pump the brake pedal firmly several times until it becomes solid. This re-seats the caliper pistons against the new pads. DO NOT skip this step — the first pedal press after a pad job will go to the floor.
7. Recheck brake fluid level once more and top off if necessary.

Verification

• With the engine/HV system off (key fob in range), pump the brake pedal until firm and verify the pedal does not sink under steady pressure.
• Inspect for any brake fluid leaks at the caliper banjo and bleeder.
• At low speed (5-10 mph) in a safe area, perform several gentle stops to confirm normal brake feel and no pulling to one side.
• Perform a proper pad bed-in procedure per the pad manufacturer's instructions (typically 6-10 moderate stops from ~35 mph followed by a cool-down period). Avoid hard stops until bed-in is complete.
• After the first 50-100 miles, re-check wheel lug nut torque and re-inspect the calipers for any signs of leakage or unusual pad wear.
• Reminder: Tesla recommends brake fluid replacement every 2 years regardless of mileage — if your fluid is past that interval, schedule a full system flush.

More procedures for this vehicle