Replacement of a brake caliper bracket on the 2024 Tesla Roadster Tri Motor. Note: The next-generation Roadster is not built on the Lotus Elise platform (that was the 2008-2012 original); this procedure assumes the production Roadster's conventional hydraulic disc brake architecture and uses generic language where Tesla-specific service data has not been publicly verified.

Warnings

Tools required

Parts

• Caliper bracket (manufacturer-specified for this corner) × 1 — Refer to Tesla Parts Catalog for the specific corner being serviced
• Caliper bracket mounting bolts (if single-use per OEM) × 2 — OEM specification — replace if torque-to-yield or specified single-use

Preparation

1. Park on level ground, place in P, engage 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 (or 16V/48V on applicable models) low-voltage battery per the Tesla Service Manual location for this vehicle. See architecture notes for 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. Place Service Mode is NOT required for this job, but if accessible via the touchscreen, enable it to disable auto-wake and unwanted system activation.
7. Chock the wheels that will remain on the ground.
8. Loosen the lug nuts on the affected wheel while the vehicle is still on the ground.
9. Raise the vehicle at the manufacturer-specified jacking points and support on jack stands. Never work under a vehicle supported only by a jack.
10. Confirm you have the correct replacement bracket for the specific corner (front/rear, left/right) — front and rear bracket torque specifications differ on this vehicle.

Procedure

1. 1

   Remove the wheel
   Fully remove the lug nuts and pull the wheel straight off the hub. Set the wheel face-down to protect the finish. Inspect the hub face for corrosion or debris.
2. 2

   Inspect brake assembly
   Visually inspect the caliper, bracket, pads, rotor, and flexible brake hose. Photograph the assembly before disassembly to document hardware orientation, shim placement, and hose routing.
3. 3

   Support the caliper
   Position a caliper hanger or bungee from a suspension component to support the caliper once removed. The flexible brake hose must NEVER bear the weight of the caliper.
   ⚠Hanging the caliper by the brake hose can damage the hose internally and cause a future failure.
4. 4

   Remove the caliper from the bracket
   Remove the caliper slide pin bolts (or caliper-to-bracket bolts, depending on the design fitted to this corner). Slide the caliper off the bracket and rotor, then secure it to the hanger. Do not disconnect the brake hose unless the hose itself is being replaced — keeping the hydraulic system sealed avoids a bleed procedure.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)

   Caliper Bolts88 Nm (65 lb-ft)
5. 5

   Remove the brake pads
   Remove the brake pads from the bracket, noting the orientation of any anti-rattle clips, shims, or wear sensors. Set pads aside on a clean surface in the order/orientation removed.
6. 6

   Remove the rotor (if required for bracket access)
   If the bracket geometry requires rotor removal for access, remove the rotor retaining clip/screw (if fitted) and slide the rotor off the hub. On many designs the bracket can be removed with the rotor in place — verify before proceeding.
7. 7

   Remove the caliper bracket
   Remove the two caliper bracket mounting bolts that secure the bracket to the steering knuckle (front) or rear upright. These bolts are typically very tight and may have factory thread-locker — use a breaker bar with a properly seated socket to avoid rounding the head. Remove the bracket from the vehicle.
   ⚠If a bolt will not break loose with reasonable force, STOP. Heating or impact methods near aluminum knuckles or HV harness routing can cause damage.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
8. 8

   Clean the mounting surface
   Wire-brush the bracket mounting bosses on the knuckle/upright to remove rust and old thread-locker residue. Clean the bolt threads (or use new bolts if specified by Tesla as single-use). Inspect threads in the knuckle for damage; chase with the correct thread tap only if necessary and only with the manufacturer's approval.
9. 9

   Install the new caliper bracket
   Position the new bracket against the knuckle/upright. Apply medium-strength thread-locking compound to the bracket bolt threads (threadlocker is recommended on the front bracket bolts per the verified data). Hand-thread both bolts fully before applying torque to avoid cross-threading.
10. 10

    Torque the caliper bracket bolts
    Torque the bracket bolts to the verified specification for this corner: front bracket bolts to 120 Nm (88 lb-ft); rear/general bracket bolts to 102 Nm (75 lb-ft). If the corner being serviced is not explicitly covered, torque to OEM specification — refer to the Tesla Service Manual. Tighten in the sequence specified by the service manual.
    ⚠Front and rear bracket torque values differ. Confirm which corner you are servicing before applying final torque.
    Torque spec

    Bracket Bolts102 Nm (75 lb-ft)
11. 11

    Reinstall the rotor (if removed)
    Slide the rotor back onto the hub. Reinstall any retaining clip or screw if fitted. Verify the rotor seats flat against the hub face with no debris between mating surfaces.
12. 12

    Reinstall the brake pads
    Install the brake pads into the new bracket with all shims, clips, and wear sensors in the same orientation as removed. Apply a thin film of silicone brake grease to pad backing-plate contact points and abutment clips — never on the friction surface or rotor.
13. 13

    Reinstall the caliper
    Slide the caliper over the pads and onto the bracket. If the caliper pistons need to be retracted to clear new pads, use a proper caliper piston tool — note that some EV calipers with electric parking brake actuators require a scan tool to retract; if this corner has an EPB and you cannot retract the piston manually, STOP and consult the Tesla Service Manual. Apply silicone brake grease to slide pins. Apply thread-locker to caliper bolts where specified.
    ⚠Forcing an EPB-equipped piston back without the proper retract procedure will damage the actuator.
14. 14

    Torque the caliper fasteners
    Torque caliper slide pin bolts to 35 Nm (26 lb-ft), or caliper mounting bolts to 88 Nm (65 lb-ft) / 102 Nm (75 lb-ft) depending on which fastener type is used at this corner. If unsure which fastener category applies, torque to OEM specification — refer to Tesla Service Manual.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)

    Caliper Bolts88 Nm (65 lb-ft)

    Caliper Mounting Bolts102 Nm (75 lb-ft)
15. 15

    Reinstall the wheel
    Mount the wheel on the hub and hand-thread all lug nuts. Lower the vehicle until the tire just contacts the ground, then torque the lug nuts to 140 Nm (103 lb-ft) in a star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Reconnect the 12V/LV battery.
2. With the vehicle on the ground and the brake system fully reassembled, press the brake pedal firmly multiple times before driving. The pedal must come up firm — if it is soft or sinks, STOP and inspect for hydraulic issues or improper pad seating.
3. If the brake hose was disconnected at any point, bleed the system using DOT 3 brake fluid and torque the banjo bolt to 41 Nm (30 lb-ft) with NEW copper washers.
4. Power the vehicle on and clear any chassis/brake-related faults that may have set during the LV disconnect. Verify ABS, traction control, and EPB indicators extinguish normally.

Verification

• Confirm pedal feel is firm and consistent — no sponginess or fade.
• Perform a low-speed (5–10 mph) stop in a safe area to confirm even braking with no pulling, dragging, or unusual noise.
• Re-check both bracket bolts for proper torque after the first low-speed test stop.
• Bed in the new pads (if pads were replaced) per the pad manufacturer's procedure — typically a series of moderate stops from ~35 mph followed by a cool-down period. Avoid hard stops or holding the brake at a stop while pads are still hot.
• Verify no brake fluid leaks at any fitting that was disturbed.
• Confirm no warning lights remain on the touchscreen after a short test drive.
• Note: Tesla recommends brake fluid replacement every 2 years regardless of mileage — log this service date and check fluid age while the vehicle is in for this job.

More procedures for this vehicle