Replace a front flexible brake hose on the 2024 Tesla Roadster (Tri Motor AWD). Note: this vehicle's chassis derives from Lotus heritage in early prototypes; production hardware specifics are limited, so verify all fitment against the official Tesla Service Manual before proceeding.

Warnings

Tools required

Parts

• Front brake hose assembly (manufacturer-specified for 2024 Roadster) × 1 — OEM Tesla front brake hose — verify with Service Manual
• Copper sealing washers for banjo fitting × 2 — OEM-spec copper crush washers, sized to banjo bolt
• Retaining clip for hose-to-bracket (if equipped) × 1 — OEM-spec horseshoe/R-clip

Fluids

• DOT 3 Brake Fluid (sealed, fresh container) — 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 architecture notes for this vehicle. If the LV battery location is unclear, consult the Tesla Service Manual before proceeding.
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. Chock the rear wheels. Loosen the front lug nuts on the affected side while the wheel is still on the ground.
7. Raise the front of the vehicle and support it on jack stands at the manufacturer-specified lift points. The Roadster uses lightweight chassis construction — never lift on suspension arms or sheet metal.
8. Remove the front wheel on the affected side.
9. Confirm which side(s) the hose is being replaced on; have the new hose, new copper washers, and fresh sealed DOT 3 fluid ready before opening the hydraulic system.

Procedure

1. 1

   Cover and protect surrounding components
   Place absorbent rags below the caliper and along the hose route to catch dripping brake fluid. Cover any painted or composite body sections near the work area.
2. 2

   Minimize fluid loss
   Optionally clamp the upstream rigid line with a rubber-jaw brake hose pinch-off tool, or top off the master cylinder reservoir and seal its cap with plastic film to slow siphoning. Do not crimp metal hard lines.
   ⚠Use only rubber-jaw clamps designed for brake hoses. Standard pliers will damage the hose internally.
3. 3

   Disconnect the rigid line at the hose's chassis end
   Locate the hose's upper fitting where it meets the chassis-mounted hard line. Using a line/flare wrench, hold the hose hex steady and back off the hard-line fitting nut. Allow fluid to drip into the catch pan.
   ⚠Always use a line wrench, not an open-end wrench, to avoid rounding the soft fitting.
   Torque spec

   Line Fittings20 Nm (15 lb-ft)
4. 4

   Free the hose from the chassis bracket
   Remove the retaining clip (typically a horseshoe/R-clip) securing the hose's upper end to the chassis bracket. If the hose is secured by a separate bracket bolt instead of a clip, remove that fastener now.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
5. 5

   Disconnect the banjo fitting at the caliper
   At the caliper end, unscrew the banjo bolt securing the hose to the caliper. Capture the two copper washers (one on each side of the banjo eye) and discard them — they will be replaced with new washers. Allow remaining fluid to drain into the catch pan.
   ⚠Discard the old copper washers immediately so they cannot be accidentally reinstalled.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
6. 6

   Remove the old hose
   Carefully remove the hose from the vehicle, noting its routing, any anti-rotation tabs, and intermediate bracket clips. Photograph routing before full removal if helpful.
7. 7

   Inspect mating surfaces
   Inspect the caliper banjo seat and the chassis-side hard line fitting for corrosion, debris, or damage. Wipe both clean with a lint-free cloth dampened with fresh brake fluid. Replace any damaged hard line.
8. 8

   Install the new hose at the caliper (banjo end)
   Place a new copper washer on each side of the banjo eye, position the hose so it does not twist throughout suspension travel, and start the banjo bolt by hand. Once seated, torque to specification. Confirm anti-rotation tab (if present) is properly indexed.
   ⚠Verify the hose will not contact suspension or steering components through full lock and full travel.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
9. 9

   Secure the hose to the chassis bracket
   Route the hose along its original path. Seat the upper end into the chassis bracket and install the retaining clip (or bracket bolt, as applicable). Ensure no twist is induced in the hose.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
10. 10

    Reconnect the rigid line
    Thread the hard-line fitting into the hose's upper end by hand to avoid cross-threading. Snug with a line wrench while holding the hose hex with a second wrench, then torque to specification.
    Torque spec

    Line Fittings20 Nm (15 lb-ft)
11. 11

    Bleed the brake circuit
    Top up the master cylinder reservoir with fresh DOT 3 fluid. Bleed the affected caliper using the bleeder screw — pressure bleeder or two-person pedal method — until clean, bubble-free fluid is observed. Maintain reservoir level throughout. If the entire system was opened, follow the Tesla-specified bleed sequence (typically furthest from master cylinder first).
    ⚠Never let the master cylinder run dry during bleeding — air will enter the ABS module and require a scan-tool bleed procedure.
    ℹ️If the system ingested air into the ABS unit, a Tesla-Toolbox-equipped technician must perform an automated ABS bleed. Stop and refer the vehicle out if so.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
12. 12

    Final pressure check
    With the bleeder closed and reservoir topped to MAX, have an assistant hold firm pressure on the brake pedal while you inspect the banjo, hard-line fitting, and bleeder for any seepage. Wipe each joint dry and re-check after several pumps.

Reassembly

1. Confirm master cylinder reservoir is filled to the MAX line with fresh DOT 3 fluid and reinstall the cap.
2. Reinstall the front wheel. 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 to specification.
5. Reconnect the low-voltage battery.
6. Wipe down any fluid spills with water and clean rags.
7. Dispose of used brake fluid and old copper washers per local hazardous-waste regulations.

Verification

• With the vehicle stationary and ignition on, press the brake pedal firmly several times — pedal should be firm and high, not spongy. A soft pedal indicates remaining air in the system.
• Visually inspect the banjo fitting, chassis-side hard-line fitting, and bleeder screw for any sign of weeping after 5+ firm pedal applications.
• Turn the steering full lock to full lock with the suspension at ride height; confirm the new hose does not contact tire, suspension, or body components and does not twist.
• Perform a low-speed road test (under 15 mph) in a safe area, applying brakes progressively. Confirm straight, even stopping with no pull.
• Check the vehicle's instrument cluster / center display for any ABS, traction control, or brake warning messages. If any appear, stop and have the system scanned.
• Re-inspect all fittings after the road test for leaks.
• Reminder: Tesla recommends a full brake fluid flush every 2 years — log this service date so the next interval can be tracked.

More procedures for this vehicle