Rebuild of the rear brake calipers on the 2024 Tesla Roadster Tri Motor. This vehicle's chassis and brake hardware are unconventional for a Tesla; service data is extremely limited and many components may be sourced from non-Tesla suppliers. Proceed only with OEM-confirmed rebuild kits.

Warnings

Tools required

Parts

• Manufacturer-specified rear caliper rebuild kit (piston seals, dust boots, bleeder cap) × 2 — OEM rear caliper seal/boot kit for Roadster Tri Motor — confirm with Tesla parts
• Caliper piston (if scored or pitted) × 2 — OEM replacement piston — inspect before ordering
• Crush washers for brake line banjo / fitting (if applicable) × 4 — Per OEM specification
• Brake pads (recommended replacement during rebuild) × 1 — OEM rear pads for Roadster Tri Motor

Fluids

• DOT 3 Brake Fluid (verify against current OEM specification before use) — 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. See architecture notes for the Roadster's LV battery location — confirm before cutting power.
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. Confirm whether the rear caliper is equipped with an electronic parking brake actuator. If so, place the EPB into service mode per the OEM procedure before any disassembly.
7. Loosen rear lug nuts while wheels are on the ground.
8. Raise the rear of the vehicle and support securely on jack stands at the manufacturer-specified lift points. The Roadster's chassis lift points are NOT identical to other Teslas — verify before lifting.
9. Remove rear wheels.
10. Place a catch pan under the caliper area to collect brake fluid.

Procedure

1. 1

   Inspect and document caliper assembly
   Photograph the caliper, brake line routing, and any electronic connectors (parking brake actuator, pad wear sensors). Note orientation of any anti-rattle clips and shims. Confirm caliper design (fixed multi-piston vs. floating sliding) — this dictates the rebuild approach.
2. 2

   Disconnect electronic parking brake (if equipped)
   If the rear caliper has an EPB motor, ensure it is in service/retract mode. Disconnect the electrical connector. Do NOT pry the actuator off — remove its mounting fasteners per OEM procedure.
   ⚠Forcing piston retraction on an EPB-equipped caliper without service mode can destroy the actuator gearset.
3. 3

   Remove brake pads
   Remove pad retaining hardware (clips, pins, or slide pin bolts depending on caliper design). Withdraw pads and inspect for uneven wear that may indicate a sticking piston or slide.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
4. 4

   Disconnect brake hydraulic line
   Place a catch pan beneath the fitting. Using a line wrench, loosen the brake line fitting at the caliper. Cap the line immediately to prevent excessive fluid loss and contamination. Discard any crush washers — these are single-use.
   ⚠Use a flare-nut/line wrench only — an open-end wrench will round the fitting.
   Torque spec

   Line Fittings20 Nm (15 lb-ft)
5. 5

   Remove caliper from vehicle
   Support the caliper, then remove the caliper-to-bracket bolts (or bracket-to-knuckle bolts depending on design). Lift the caliper away. If removing the bracket as well, note bolt orientation.
   Torque spec

   Caliper Bolts88 Nm (65 lb-ft)

   Bracket Bolts102 Nm (75 lb-ft)
6. 6

   Extract caliper pistons
   Place the caliper on a workbench with a thick wood/rag pad facing the pistons. Using low-pressure compressed air through the fluid inlet, gently walk the piston(s) out. For multi-piston calipers, extract one at a time using a piston clamp on the others. Inspect each piston for scoring, pitting, or corrosion — replace if not perfectly smooth.
   ⚠️Keep fingers clear of the piston bore — pistons can eject with significant force.
7. 7

   Remove and discard old seals and dust boots
   Using a non-marring seal pick, remove the dust boot and the square-cut piston seal from each bore. Do NOT scratch the bore surface — any gouge will cause leaks. Discard all old seals.
   ⚠A scratched piston bore cannot be rebuilt — the caliper must be replaced.
8. 8

   Clean and inspect caliper body
   Clean the caliper body and bores thoroughly with brake cleaner. Inspect bores for corrosion, scoring, or pitting. Inspect slide pins and boots (if floating caliper) — replace boots if torn. Clean slide pin bores and lubricate per OEM spec with silicone brake grease.
9. 9

   Install new seals and reassemble pistons
   Lubricate new piston seals with clean brake fluid and install in the bore grooves. Install new dust boots per the kit instructions (some seat in the caliper first, others on the piston). Lubricate piston exterior with clean brake fluid and press squarely into the bore by hand until fully seated. Verify boot is properly captured in both grooves.
   ⚠Use ONLY clean brake fluid as assembly lube on hydraulic components — petroleum products will swell and destroy seals.
10. 10

    Reinstall caliper bracket and caliper
    If bracket was removed, clean threads and apply threadlocker per OEM spec. Install bracket bolts and torque to specification. Install caliper onto bracket; for caliper bolts requiring threadlocker, apply medium-strength compound. Torque in two stages.
    Torque spec

    Bracket Bolts102 Nm (75 lb-ft)

    Caliper Bolts88 Nm (65 lb-ft)

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
11. 11

    Reinstall pads and brake line
    Install brake pads with anti-rattle hardware in the original orientation. Reconnect brake hydraulic line using NEW crush washers. Torque the line fitting using a line wrench.
    Torque spec

    Line Fittings20 Nm (15 lb-ft)
12. 12

    Reconnect EPB actuator (if equipped)
    Reinstall and torque the EPB actuator mounting fasteners to OEM specification. Reconnect the electrical connector. The actuator will need to be commanded back to operating mode after 12V is restored.
13. 13

    Bleed the brake system
    Top off the master cylinder with fresh DOT 3 brake fluid. Bleed each caliper in the OEM-specified sequence (typically furthest from master cylinder first). Continue until clean, bubble-free fluid flows. Tesla recommends a full system flush every 2 years — this is an opportunity to replace all fluid.
    ⚠Do not allow the master cylinder reservoir to run dry during bleeding — this will introduce air into the ABS/booster module which may require diagnostic-tool-assisted bleeding.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
14. 14

    Reinstall wheels
    Mount rear wheels. Hand-thread all lug nuts, then snug in a star pattern. Lower vehicle to the ground and final-torque in a star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Reconnect the 12V/LV battery.
2. If equipped with EPB, follow the OEM procedure to return the parking brake actuator to operating mode (may require diagnostic tool).
3. With the vehicle stationary and engine off, pump the brake pedal until firm before any movement — DO NOT drive until pedal is solid.
4. Inspect all fittings, bleeder screws, and the caliper body for leaks before road testing.
5. Confirm brake fluid reservoir is at the correct level.

Verification

• With the vehicle stopped, pump the brake pedal — it should reach firm resistance within 1-2 strokes and not slowly sink under steady pressure.
• Check for any brake fluid leaks at the caliper bleeder, line fitting, and piston dust boots after pumping the pedal.
• Drive at very low speed in a safe area and confirm both rear brakes engage evenly with no pulling.
• Verify the parking brake holds the vehicle on a moderate incline (if EPB-equipped, confirm no fault messages on the center display).
• Perform a controlled moderate-speed stop and confirm even braking with no vibration, pulling, or unusual noise.
• Check for any brake-related warnings on the instrument display.
• Note the date and mileage — Tesla recommends complete brake fluid replacement every 2 years regardless of mileage; if a full flush was not performed during this rebuild, schedule one.

More procedures for this vehicle