Replace a front brake caliper on the 2024 Tesla Roadster (Tri Motor AWD). Note: this generation Roadster is a clean-sheet Tesla design (not the original Lotus-based Roadster); however, detailed factory service data for this vehicle is extremely limited at time of writing — verify all specifications against the official Tesla Service Manual before proceeding.

Warnings

Tools required

Parts

• Front brake caliper (manufacturer-specified, side-specific) × 1 — OEM Tesla Roadster front caliper — verify L/R
• Copper crush washers for banjo fitting × 2 — Sized to OEM banjo bolt
• Brake pads (recommended if worn or contaminated) × 1 — OEM-spec front pad set
• DOT 3 brake fluid (sealed container) × 1 — DOT 3 per Tesla specification

Fluids

• DOT 3 Brake Fluid — 1 qt

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Exit ALL doors with 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 for this vehicle.
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 wheel chocks behind the rear wheels.
7. Loosen the front wheel lug nuts while the vehicle is on the ground, then raise the front of the vehicle and support on jack stands at the manufacturer-specified lift points.
8. Remove the front wheel on the affected side.
9. Inspect the caliper, hose, rotor, and pads before disassembly to confirm the failure mode.

Procedure

1. 1

   Relieve brake system pressure and prepare fluid containment
   Place a catch pan beneath the caliper. Have a sealed container of fresh DOT 3 fluid, new copper washers, and rags ready. Do not pump the brake pedal with the line open.
   ⚠Brake fluid will drip from the disconnected hose — protect aluminum bodywork and painted surfaces.
2. 2

   Disconnect the brake hose at the caliper
   Using a line wrench, loosen the banjo bolt (or fitting, depending on the OEM hose configuration) at the caliper. Capture the two copper crush washers; discard them — new washers are mandatory on reassembly. Cap or plug the hose end immediately to minimize fluid loss and air ingress.
   ⚠Do not twist the flexible hose. Hold the hose fitting stationary while loosening the bolt.
3. 3

   Remove the caliper from the bracket / knuckle
   Remove the caliper mounting bolts. Depending on the Roadster's caliper design, these may be the slide/guide pin bolts retaining the caliper to a bracket, or main mounting bolts retaining a monobloc caliper directly to the upright. Support the caliper as the last bolt comes out.
4. 4

   Remove brake pads (if reusing or replacing)
   Slide the pads out of the caliper or bracket. Note the orientation of any anti-rattle clips, shims, or wear sensors. If a wear sensor harness is present, disconnect it at the chassis-side connector.
5. 5

   Remove caliper bracket (if equipped and being replaced)
   If the Roadster uses a separate caliper bracket and it is being replaced or removed for access, remove the two bracket-to-knuckle bolts. If the bracket is staying in place, skip this step.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
6. 6

   Inspect rotor, hub face, and hardware
   Inspect the rotor for scoring, cracks, heat checking, and minimum thickness per OEM specification. Clean the hub face and bracket mating surfaces. Verify the flexible hose for cracks, swelling, or chafing — replace if compromised.
7. 7

   Install the new (or rebuilt) caliper bracket if removed
   Apply medium-strength thread locker to the bracket bolt threads. Install the bracket and torque the bolts to specification.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
8. 8

   Install brake pads
   Install pads with all anti-rattle clips and shims in their original orientation. Apply a thin film of high-temperature brake-specific lubricant to pad backing contact points only — never on the friction surface or rotor.
9. 9

   Install the new caliper
   Mount the new caliper over the pads/rotor. Apply medium-strength thread locker to the caliper mounting bolt threads as specified. Start all bolts by hand to avoid cross-threading, then torque to specification.
   ⚠Confirm the caliper is correctly oriented (bleeder screw at the top) before final torque.
10. 10

    Reconnect the brake hose with NEW copper washers
    Install the banjo bolt with one new copper washer on each side of the hose fitting. Torque to specification. Verify the hose is not twisted and clears all suspension travel.
    ⚠️Reusing old copper washers will leak. Always use new washers.
11. 11

    Bleed the caliper
    Top off the master cylinder reservoir with fresh DOT 3 fluid. Bleed the new caliper at the bleeder screw using a vacuum or pressure bleeder until clear, bubble-free fluid flows. Torque the bleeder screw carefully — it is easy to strip. Bleed sequence should follow the Tesla Service Manual; if unavailable, bleed the corner that was opened and verify pedal feel.
    ⚠Do not let the master cylinder run dry during bleeding — this introduces air into the ABS/booster system and may require Tesla diagnostic equipment to fully purge.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
12. 12

    Pedal pressure check
    With the vehicle still on stands, slowly pump the brake pedal to seat the pads against the rotor. Pedal should become firm within several pumps. Inspect the banjo connection and bleeder for any weeping. Re-torque or re-bleed as needed.

Reassembly

1. Reinstall the front wheel; snug lug nuts by hand.
2. Lower the vehicle to the ground.
3. Torque the wheel lug nuts in a star pattern to specification.
4. Reconnect the 12V/LV battery.
5. Top off the brake fluid reservoir to the MAX line with fresh DOT 3 fluid.
6. Clean any spilled brake fluid from suspension, bodywork, and the rotor face with brake cleaner.

Verification

• With the vehicle stationary, confirm a firm brake pedal that does not sink under sustained pressure.
• Visually inspect the banjo fitting, bleeder, and hose routing for leaks after pedal pressurization.
• Power up the vehicle and check the instrument cluster for any ABS, brake, or stability control warnings. If any are present, a Tesla-capable scan tool may be required to clear/diagnose.
• Perform a low-speed brake test in a safe area (5-10 mph) and confirm even, straight-line braking with no pull, vibration, or noise.
• Gradually increase test speed to bed in new pads per pad manufacturer instructions; expect reduced regen-only driving for the first several stops to allow proper bedding.
• Recheck banjo bolt and bleeder for leaks after the test drive.
• Note: Tesla recommends brake fluid replacement every 2 years regardless of mileage. Log this service date and plan a full flush at the next interval.

More procedures for this vehicle