Replace a single rear brake rotor on a 2012 Tesla Roadster. Note that the Roadster is built on the Lotus Elise platform, so most brake components are Lotus/AP Racing-style hardware rather than Tesla-specific parts.

Warnings

Tools required

Parts

• Rear brake rotor (Lotus Elise/Roadster-spec) × 1 — OEM-equivalent rear rotor for 2012 Tesla Roadster
• Rotor retaining set screw (if damaged on removal) × 1 — Lotus-style rotor set screw
• Brake pads (recommended to replace as a pair if worn) × 1 — Rear brake pad set, Roadster-spec

Fluids

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

Preparation

1. Park on level ground, place transmission in 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 (located in the Roadster's front compartment area — refer to owner documentation for exact location on this chassis).
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. Raise the rear of the vehicle using manufacturer-specified jacking points and support securely on jack stands. Never rely on the jack alone.
8. Remove the rear wheel on the side being serviced.
9. Inspect the caliper, pads, hose, and rotor for damage, fluid leaks, or excessive wear before disassembly.

Procedure

1. 1

   Inspect and document
   With the wheel off, photograph the caliper, bracket, and rotor orientation. Note the position of any shims, anti-rattle clips, or pad wear sensors. The Roadster's rear brake assembly resembles the Lotus Elise — confirm hardware is fully accounted for before disassembly.
2. 2

   Retract the caliper piston (if replacing pads)
   If pads will be replaced or the caliper needs to clear a thicker new rotor, gently retract the piston using a C-clamp or caliper piston tool, pressing against the old pad. Monitor the brake fluid reservoir — fluid will rise. Remove fluid with a clean syringe if it approaches the MAX line.
   ⚠Do not let brake fluid contact paint or composite body panels — it will damage the finish.
3. 3

   Remove the caliper slide/guide bolts
   Loosen and remove the caliper slide pin bolts (or caliper-to-bracket bolts, depending on configuration). Support the caliper — do NOT let it hang by the flexible brake hose.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
4. 4

   Suspend the caliper
   Lift the caliper off the rotor and suspend it from a suspension component using a caliper hanger or wire. Keep the brake hose unkinked and unstressed.
   ⚠Never allow the caliper to hang by the brake hose — this can damage the hose internally and cause a future failure.
5. 5

   Remove brake pads (if accessing for inspection or replacement)
   Slide the brake pads out of the caliper bracket. Note orientation and any shims/clips. Inspect for uneven wear that might indicate a sticking slide pin or piston.
6. 6

   Remove the caliper bracket
   Remove the caliper bracket bolts that secure the bracket to the rear hub/upright. These are high-torque fasteners — use a breaker bar if necessary. Set the bracket aside on a clean surface.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
7. 7

   Remove the rotor set screw
   The Roadster (Lotus-derived) uses a small countersunk set screw retaining the rotor to the hub. Use a properly-fitting hex/Torx bit. If seized, apply penetrating oil and use an impact driver — these screws strip easily. Replace if damaged.
   ⚠The rotor set screw heads are soft and prone to stripping. Use the correct bit and steady pressure.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
8. 8

   Remove the rotor
   Pull the rotor off the hub. If corroded in place, apply penetrating oil to the hub center and tap evenly around the rotor hat with a soft mallet. Do NOT strike the rotor face or the hub flange directly with a steel hammer.
   ⚠Avoid striking aluminum suspension or hub components with a steel hammer — use a brass or rubber mallet.
9. 9

   Clean the hub face
   Wire-brush the hub mounting face until clean and flat. Any rust or debris between the hub and rotor will cause runout and brake judder. Apply a very thin coat of anti-seize to the hub center (NOT the friction surface or wheel mating face).
10. 10

    Install the new rotor
    Wipe the new rotor's friction surfaces with brake cleaner to remove shipping oil. Place the rotor on the hub and secure with the set screw.
    Torque spec

    Rotor Set Screws7 Nm (5 lb-ft)
11. 11

    Reinstall the caliper bracket
    Apply medium-strength threadlocker to the caliper bracket bolt threads. Reinstall the bracket and torque to specification.
    Torque spec

    Bracket Bolts102 Nm (75 lb-ft)
12. 12

    Reinstall pads and caliper
    Reinstall brake pads (and any shims/clips) into the bracket. Apply silicone brake grease to caliper slide pins. Reinstall caliper over the rotor and torque the slide pin bolts to specification.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)

Reassembly

1. Reinstall the rear wheel and hand-tighten lug nuts.
2. Lower the vehicle until the tire just contacts the ground.
3. Torque the wheel lug nuts in a star pattern to specification.
4. Reconnect the 12V low-voltage battery.
5. Before driving: with the engine/vehicle off, pump the brake pedal repeatedly until firm. This seats the pads against the new rotor. Do NOT skip this step — first pedal application after caliper removal will go to the floor.
6. Check the brake fluid reservoir level and top off with DOT 3 if needed.
7. If brake fluid is older than 2 years, perform a full brake fluid flush per Tesla's 2-year service interval.

Verification

• With the vehicle stationary and off, pump the brake pedal — it must become firm and hold pressure.
• Check for any fluid leaks at the caliper and bleeder.
• Perform a low-speed (5-10 mph) brake test in a safe area before road driving — confirm the vehicle stops straight with no pulling, grinding, or unusual noise.
• Bed in the new rotor and pads per the pad manufacturer's procedure (typically a series of moderate stops from 30-40 mph, avoiding hard stops until bed-in is complete).
• After the first short drive, re-check wheel lug nut torque and inspect for any leaks or loose hardware.
• Note: Tesla recommends brake fluid replacement every 2 years regardless of mileage — log this service date if applicable.
• After 50-100 miles, re-inspect rotor seating and caliper hardware for any signs of movement or wear.

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