Replacement of a rear flexible brake hose on the 2024 Tesla Roadster (Tri Motor AWD). Note: this vehicle is a low-volume, low-documentation platform; verify all fastener locations and torque sequences against the official Tesla Service Manual before proceeding.

Warnings

Tools required

Parts

• Rear brake hose (manufacturer-specified for 2024 Roadster) × 1 — OEM rear flex hose — verify with Tesla Parts
• Copper sealing washers for banjo fitting × 2 — OEM copper crush washers, sized to banjo bolt

Fluids

• DOT 3 Brake Fluid (sealed, fresh container) — 1 qt

Preparation

1. Park on level ground, place in P, 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 (or 16V/48V on applicable models) low-voltage battery. Refer to the Tesla Service Manual for the exact battery location on this Roadster — the Lotus-derived chassis differs from other Tesla models.
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 front wheels.
7. Loosen the rear lug nuts slightly while the vehicle is on the ground.
8. Raise the rear of the vehicle at manufacturer-specified jacking points and support on jack stands. Never rely on the jack alone.
9. Remove the rear wheel on the side being serviced.
10. Place a fluid catch pan beneath the work area; have brake line plugs/caps ready to limit fluid loss.
11. Top off the brake fluid reservoir with fresh DOT 3 before disconnecting any line — and monitor it during the job to prevent the master cylinder from running dry.

Procedure

1. 1

   Inspect and document hose routing
   Before disturbing anything, photograph the existing hose routing, retaining clip locations, and bracket orientation. The Roadster's rear suspension routing is not well documented publicly — your photos are your service manual.
2. 2

   Clean fittings
   Wire-brush and wipe clean the banjo fitting at the caliper end and the hard-line fitting at the chassis/frame end. Contamination entering the hydraulic system can damage ABS components.
3. 3

   Disconnect the hard line at the chassis end
   Using a flare-nut (line) wrench, hold the hose hex with an open-end wrench and loosen the hard-line tube nut. Allow fluid to drip into the catch pan. Cap the hard line immediately to prevent contamination and minimize fluid loss.
   ⚠Always use a flare-nut wrench on hydraulic fittings. An open-end wrench will round the soft tube nut.
   Torque spec

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

   Release the hose from the chassis bracket
   Remove the retaining clip (typically a horseshoe/U-clip) securing the hose end to the chassis bracket. If the hose is secured by a separate bolted bracket, remove that fastener now.
   Torque spec

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

   Remove any intermediate hose retainers
   Trace the hose toward the caliper and release any intermediate clips or P-clamps along the suspension upright. Note the routing direction relative to suspension travel — incorrect routing can cause the hose to chafe or stretch at full droop/compression.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
6. 6

   Disconnect the banjo bolt at the caliper
   Place the catch pan under the caliper. Remove the banjo bolt at the caliper inlet and recover the two copper washers (one on each side of the banjo fitting). Discard the old washers — do not reuse. Cap the caliper port to keep fluid in and dirt out.
   ⚠New copper washers are mandatory. Reused washers will weep fluid.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
7. 7

   Remove the old hose
   Withdraw the old hose from its routing path. Compare it side-by-side with the new hose to confirm length, fitting orientation, and any pre-formed bends match.
8. 8

   Install the new hose at the caliper
   Position the new hose at the caliper using NEW copper washers — one between the bolt head and the banjo, one between the banjo and the caliper. Hand-thread the banjo bolt to avoid cross-threading, then torque to spec. Ensure the banjo orientation matches the original to avoid kinking.
   ⚠Verify torque sequence and banjo clocking against the Tesla Service Manual for this vehicle.
   Torque spec

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

   Route hose and secure intermediate brackets
   Route the hose along the original path. Cycle the suspension by hand (or check at full droop and full compression) to confirm no contact with tire, suspension arms, or body. Install any intermediate bracket fasteners.
   Torque spec

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

    Connect the hard line at the chassis end
    Seat the hose end into the chassis bracket and install the retaining clip. Hand-start the hard-line tube nut into the hose fitting (use a flare-nut wrench) to avoid cross-threading, then torque to spec. Hold the hose hex with an open-end wrench while torquing so the hose does not twist.
    Torque spec

    Line Fittings20 Nm (15 lb-ft)

    Brake Hose Bracket10 Nm (7 lb-ft)
11. 11

    Bleed the rear brake circuit
    Top off the master cylinder reservoir with fresh DOT 3. Bleed the affected caliper using your preferred method (vacuum, pressure, or two-person pedal). Continue until clean, bubble-free fluid emerges. Torque the bleeder screw to spec on final close. Maintain reservoir level throughout — do not let it run dry.
    ℹ️Tesla recommends a full brake fluid flush every 2 years. With the system already open, consider bleeding all four corners with fresh fluid.
    Torque spec

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

    Leak check under pressure
    With the bleeder closed, have an assistant firmly press and hold the brake pedal while you inspect the banjo fitting, chassis-end fitting, and bleeder for any seepage. Wipe dry and re-inspect after several pedal applications.

Reassembly

1. Confirm reservoir is filled to the MAX line with fresh DOT 3.
2. Reinstall the rear wheel and torque lug nuts in a star pattern.
3. Lower the vehicle to the ground and final-torque the lug nuts.
4. Reconnect the 12V (or 16V/48V) low-voltage battery.
5. Allow the vehicle to wake and complete its self-checks before driving.

Verification

• With the vehicle stationary and engine/drive system in Ready mode, pump the brake pedal — it should be firm and not sink under sustained pressure.
• Check for any brake-related warnings on the instrument display. ABS, EBD, or low-fluid alerts indicate a problem to resolve before driving.
• Inspect the new hose, banjo, and hard-line fittings for any signs of weep after pedal pressurization.
• Perform a low-speed brake test in a safe area: confirm straight, even braking with no pull or pulsation, and recheck for leaks afterward.
• Cycle the suspension (or test-drive over a bump) and re-inspect the hose for clearance to tire, suspension components, and body — especially at full steering lock if applicable to rear hose routing.
• Log the brake fluid service date — Tesla recommends brake fluid replacement every 2 years regardless of mileage.

More procedures for this vehicle