Replace both front brake rotors on a 2012 Tesla Roadster. The Roadster shares its front brake architecture with the Lotus Elise/Exige platform, so most procedures and fasteners are Lotus-spec rather than Tesla-specific.

Warnings

Tools required

Parts

• Front brake rotor (Roadster/Lotus-spec, vented) × 2 — Manufacturer-specified front rotor for 2012 Tesla Roadster
• Rotor retaining set screws (if damaged on removal) × 2 — OEM-spec set screws

Preparation

1. Park on level ground, place 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 under the car. See architecture notes for the Roadster's 12V battery location (typically accessed via service panel).
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 on the ground.
7. Raise the front of the vehicle using manufacturer-specified jacking points and support securely on jack stands.
8. Remove both front wheels and set aside.
9. Inspect brake hoses, caliper bodies, and pads for wear or damage before disassembly.

Procedure

1. 1

   Inspect and prepare the front brake assemblies
   With wheels removed, inspect both front calipers, pads, and rotors. Note pad thickness and any uneven wear. Check that brake hoses have enough slack to support the caliper without strain once removed.
2. 2

   Remove the brake caliper
   Locate the caliper mounting bolts that secure the caliper body to its bracket (or directly to the upright, depending on configuration). Loosen and remove them. Carefully slide the caliper off the rotor without stressing the brake hose. Support the caliper with a hanger or bungee — do not let it hang by the hose.
   ⚠Do not allow the caliper to hang by the flexible brake hose — this can damage the hose internally.
   Torque spec

   Caliper Bolts88 Nm (65 lb-ft)
3. 3

   Remove the caliper bracket (if equipped)
   If the front caliper uses a separate mounting bracket bolted to the upright, remove the bracket fasteners. Note bolt orientation and any shims for reinstallation. On Lotus-derived front uprights, bracket bolts are typically high-torque and may use thread locker — heat may be required if seized.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
4. 4

   Remove the rotor set screw(s)
   Remove the small retaining set screw(s) that hold the rotor to the hub face. These are commonly seized — use a properly fitting bit and an impact driver if needed to avoid stripping. Replace any damaged set screws on reinstallation.
   ⚠Stripping the set screw head will significantly increase removal time. Use the correct bit and apply firm downward pressure.
   Torque spec

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

   Remove the rotor
   Pull the rotor straight off the hub. If the rotor is rust-bonded to the hub, apply penetrating oil at the hub-to-rotor interface and tap evenly around the rotor hat with a soft-faced mallet. Do not strike the rotor friction surface or any aluminum suspension component.
   ⚠Do not strike aluminum uprights or chassis components. Use a soft mallet only on the rotor hat.
6. 6

   Clean the hub face
   Wire-brush the hub mounting face to remove all rust and debris. The new rotor must seat flat against a clean hub to avoid runout and brake pulsation. A very thin film of anti-seize on the hub face (NOT on the friction surface) is acceptable to prevent future seizure.
7. 7

   Install the new rotor
   Clean both friction surfaces of the new rotor with brake parts cleaner to remove protective oil. Slide the rotor onto the hub and install the set screw(s) to hold it flush.
   Torque spec

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

   Reinstall the caliper bracket (if removed)
   Apply medium-strength thread locker to the caliper bracket bolts. Install the bracket and torque the fasteners. Verify sequence and pattern with the service manual.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
9. 9

   Reinstall the caliper
   If pads were removed, reinstall them per OEM orientation. If caliper pistons need to be retracted to clear the new rotor, do so using a proper piston tool — monitor the brake fluid reservoir to avoid overflow. Apply thread locker to caliper bolts and torque to spec.
   ⚠When retracting caliper pistons, brake fluid will rise in the reservoir. Remove excess fluid first if the reservoir is near full.
   Torque spec

   Caliper Bolts88 Nm (65 lb-ft)
10. 10

    Repeat for the opposite front side
    Repeat steps 2–9 on the other front corner. Always replace front rotors as a pair to maintain even braking.

Reassembly

1. Verify both calipers are fully seated and all fasteners are torqued.
2. Reinstall both front wheels. Hand-thread all lug nuts before applying torque.
3. Lower the vehicle to the ground.
4. Final-torque the wheel lug nuts in a star pattern.
5. Reconnect the 12V low-voltage battery.
6. Before driving, pump the brake pedal multiple times until firm to seat the pads against the new rotors. Never move the vehicle without a firm pedal.
7. Check brake fluid level and top off with DOT 3 if required.

Verification

• With the engine/system off, pump the brake pedal — it should become firm and not sink to the floor.
• Perform a low-speed roll test in a safe area: confirm the brakes engage smoothly without pulling, grinding, or pulsation.
• Bed the new rotors and pads per the pad manufacturer's bed-in procedure (typically a series of moderate stops from 30–40 mph followed by a cool-down).
• After the first 50–100 miles, re-check wheel lug torque (140 Nm in star pattern) and inspect for fluid leaks at caliper fittings.
• Reminder: Tesla recommends brake fluid replacement every 2 years regardless of mileage. If brake fluid age is unknown, plan a flush in the near future.

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