Replace both front brake rotors on the 2024 Tesla Roadster (Tri Motor AWD). Note: this vehicle has very limited public service documentation — verify all fastener locations and torque sequences against the official Tesla Service Manual before final assembly.

Warnings

Tools required

Parts

• Front brake rotors (matched pair) × 2 — OEM-spec front rotor for 2024 Roadster — confirm with VIN
• Rotor set screws (if damaged on removal) × 2 — OEM-spec set screw

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. See architecture notes — 2024 Roadster low-voltage battery location should be confirmed against official documentation.
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 slightly while the vehicle is still on the ground.
7. Raise the front of the vehicle and support securely on jack stands rated for the vehicle's weight at the manufacturer-specified lift points. Do NOT lift on battery enclosure or composite floor sections.
8. Remove both front wheels and set aside on a soft surface to protect the finish.
9. Inspect brake hoses, calipers, and pads for wear or damage before proceeding.

Procedure

1. 1

   Inspect and document existing hardware
   Before disassembly, photograph the caliper, bracket, and rotor orientation on both sides. Note any shims, anti-rattle clips, or pad wear sensors. The 2024 Roadster's brake hardware layout is not widely documented — your reference photos will help during reassembly.
2. 2

   Remove brake caliper (driver side first)
   Locate the caliper slide pin bolts (or caliper mounting bolts, depending on caliper design). Loosen and remove the bolts that secure the caliper body to the bracket. Carefully slide the caliper off the rotor without stressing the brake hose. Suspend the caliper from the suspension using a hanger or bungee cord — never let it hang from the hose.
   ⚠If the caliper design uses fixed-mount bolts rather than slide pins, those are higher-torque fasteners — verify against the service manual.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Remove brake pads (if required for rotor removal)
   Remove the brake pads from the caliper bracket, noting orientation and any retention clips or wear-indicator wiring. Set pads aside in a clean location; if they are being reused, mark inboard/outboard and left/right.
4. 4

   Remove caliper bracket
   Remove the two large bolts securing the caliper bracket (carrier) to the steering knuckle. These are high-torque fasteners and may require a breaker bar. Set the bracket aside.
   ⚠Verify the actual fastener size and torque against the Tesla Service Manual for the 2024 Roadster — front caliper bracket torque is listed as critical and threadlocked.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
5. 5

   Remove rotor set screw and rotor
   Remove the small rotor retaining set screw from the rotor face (typically a Torx or hex fastener). If seized, use an impact driver to avoid stripping. Pull the rotor straight off the hub. If corroded to the hub, strike the rotor hat (NOT the friction surface) with a soft mallet, or thread bolts into the rotor's threaded extraction holes if equipped.
   ⚠Do not strike aluminum suspension components or the hub face directly. Use only the rotor hat as an impact point.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
6. 6

   Clean hub face
   Wire-brush the hub mating surface to remove all rust and debris. The new rotor must seat flat against a clean hub or you will introduce lateral runout and brake pulsation. Apply a very thin film of anti-seize to the hub face only — never on lug studs, rotor friction surface, or threaded fasteners.
7. 7

   Install new rotor
   Wipe the new rotor's friction surfaces with brake cleaner to remove shipping oil. Install the rotor onto the hub and secure with the set screw. Snug only — final torque is low.
   Torque spec

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

   Reinstall caliper bracket
   Apply medium-strength threadlocker to the caliper bracket bolt threads. Install the bracket onto the steering knuckle and torque to specification. If the service manual specifies a tightening sequence for the front caliper bracket bolts, follow it.
   ⚠VERIFY tightening sequence with the Tesla Service Manual — front bracket bolts are flagged as sequence-sensitive in our database.
   Torque spec

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

   Reinstall brake pads and caliper
   Reinstall pads into the bracket with all original clips and shims oriented correctly. If caliper pistons need to be retracted to clear the new rotor and pad thickness, use a proper piston retraction tool — do not pry against the new rotor. Slide the caliper over the rotor and install the slide pin bolts. Apply silicone brake grease to slide pins per the verified spec note. Torque the slide pin bolts to specification.
   ⚠Before retracting pistons, open the brake fluid reservoir cap and monitor fluid level — retracting pistons pushes fluid back up the system.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Repeat for passenger side
    Repeat steps 2 through 9 on the passenger-side front rotor. Confirm both sides use identical hardware and torque values.
11. 11

    Reinstall wheels
    Mount each front wheel and hand-thread all lug nuts. Snug in a star pattern, then lower the vehicle to the ground and final-torque in a star pattern to specification.
    ⚠VERIFY star-pattern torque sequence — improper sequence can warp the new rotor.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Confirm brake fluid reservoir is at the correct level; top off with DOT 3 brake fluid if needed.
2. Reconnect the 12V/low-voltage battery.
3. With the vehicle still stationary and in P, pump the brake pedal repeatedly until firm pressure is restored — pistons must take up the gap to the new rotors before driving.
4. Verify pedal feel is firm and consistent before any movement.
5. Re-check torque on all critical fasteners after pedal pressure is established.

Verification

• With the vehicle stationary, confirm a firm brake pedal that does not sink under steady pressure.
• Inspect both rotors visually for proper seating against the hub (no visible gap at the hat).
• Perform a low-speed test in a safe area: light brake application from 5-10 mph to confirm no pulling, grinding, or pulsation.
• Bed in the new rotors per the rotor manufacturer's procedure (typically a series of moderate-to-firm stops from 30-40 mph, avoiding full stops at the end).
• After the test drive, re-check wheel lug torque and inspect for fluid leaks at the caliper.
• Reminder: Tesla recommends brake fluid replacement every 2 years regardless of mileage — note the date of last fluid service and schedule accordingly.
• If any ABS, traction control, or brake warning indicators appear on the instrument cluster after the work, stop driving and diagnose before further use.

More procedures for this vehicle