2025-02-25

Electromechanical Brake Booster Assembly (NA) (Remove and Replace)

Correction code TBD FRT 1.1 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

Torque Specifications

Table 1. Torque Specifications: Electromechanical Brake Booster Assembly (NA) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut that attaches the master cylinder secondary pipe from the brake booster
18 Nm (13.3 lbs-ft)
  • 12 mm 6-point flare nut crowfoot socket (mount at 90 degrees)
 Reuse
Nut that attaches the master cylinder primary pipe from the brake booster.
18 Nm (13.3 lbs-ft)
  • 12 mm 6-point flare nut crowfoot socket (mount at 90 degrees)
 Reuse
Nuts (x2) that attach the rear brake lines
18 Nm (13.3 lbs-ft)
  • 12 mm 6-point flare nut crowfoot socket (mount at 90 degrees)
 Reuse
Nuts (x2) that attach the brake assembly to the bulkhead
16.5 Nm (12.2 lbs-ft)
  • 13 mm deep socket
  • Torque wrench with angle measurement
 Replace 1111541-00-A

Remove

  1. Remove the HEPA filter assembly. See SERVICE KIT - HEPA AND CARBON FILTERS (Remove and Replace).
  2. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  3. Disconnect the LV battery. See LV Power (Disconnect and Connect).
  4. Remove the LH knee airbag assembly. See KNEE AIRBAG - LEFT HAND (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    It is not necessary to remove the airbag cover from the assembly.
  5. Place an absorbent material beneath the brake lines and brake fluid reservoir area.
  6. Clean area around the brake fluid reservoir and remove the brake fluid reservoir cap.
  7. Using a brake fluid evacuator, remove the brake fluid from the reservoir.
  8. Disconnect the brake fluid level sensor connector.
  9. Release the connector lock, and then disconnect the brake booster ECU harness connector.
  10. Remove the nut that attaches the master cylinder secondary pipe from the brake booster.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 12 mm 6-point flare nut crowfoot socket (mount at 90 degrees)
  11. Remove the nut that attaches the master cylinder primary pipe from the brake booster.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 12 mm 6-point flare nut crowfoot socket (mount at 90 degrees)
  12. Remove the nuts (x2) that attach the rear brake lines.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 12 mm 6-point flare nut crowfoot socket (mount at 90 degrees)
  13. Release the clip that attaches the brake reservoir to the redundant control unit (RCU).
  14. Release the cotter clip that attaches the brake clevis clip pin to the brake pedal assembly.
  15. Remove the brake clevis clip pin from the brake pedal assembly.
  16. Remove and discard the bolts (x2) that attach the brake assembly to the bulkhead, and then remove the brake booster assembly from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull straight out first to clear the brake pedal from IP carrier rod before lifting
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 13 mm deep socket
    • Torque wrench with angle measurement

Install

  1. Position the brake booster to the vehicle, and then install new bolts (x2) that attach the brake assembly to the bulkhead.
    16.5 Nm (12.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 13 mm deep socket
    • Torque wrench with angle measurement
  2. Align the brake pedal to the booster rod, and then install the brake clevis clip pin to the brake pedal assembly.
  3. Install the cotter clip that attaches the brake clevis clip pin to the pedal assembly.
  4. Install the LH knee airbag assembly. See KNEE AIRBAG - LEFT HAND (Remove and Replace).
  5. Install the nuts (x2) that attach the rear brake lines.
    18 Nm (13.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 12 mm 6-point flare nut crowfoot socket (mount at 90 degrees)
  6. Install the nut that attaches the master cylinder primary pipe from the brake booster.
    18 Nm (13.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 12 mm 6-point flare nut crowfoot socket (mount at 90 degrees)
  7. Install the nut that attaches the master cylinder secondary pipe from the brake booster.
    18 Nm (13.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 12 mm 6-point flare nut crowfoot socket (mount at 90 degrees)
  8. Connect the brake booster ECU harness connector.
  9. Connect the brake fluid level sensor connector.
  10. Connect the LV battery. See LV Power (Disconnect and Connect).
  11. Reinstall the software. See Software Reinstall - Touchscreen.
  12. Locally connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  13. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Chassis > Procedures > IDB Replacement > Calibrate Pedal Travel Sensor, click Run, and allow the routine to complete.
  14. Tap Chassis > Procedures > IDB Replacement > Calibrate Pressure Sensor, click Run, and allow the routine to complete.
  15. Remove all four wheels. See Wheel Assembly (Remove and Install).
  16. Add clean brake fluid to the MAX level in the brake bleeder reservoir.
  17. Add clean brake fluid to the MAX level in the brake fluid reservoir.
  18. Install the pressure bleeder adapter onto the vehicle brake reservoir.
  19. Connect power supply to the bleeder tool, and then turn the bleeder tool on.
  20. Set the brake bleed reservoir pressure to 30 PSI, and then attach the brake bleed reservoir to the brake bleed adapter.
  21. Manually bleed 4 brake calipers.
    1. Remove the LH front caliper inner bleed valve cover, and then install the fluid catcher.
    2. Open the inner bleed valve and watch the fluid as it flows out of the caliper (~20 seconds).
    3. Close the bleed valve when clean fluid without bubbles flows out of the caliper.
    4. Remove the fluid catcher, and then torque the LH front caliper bleed valve and install the valve cap.
      18.5 Nm (13.6 lbs-ft)
      Informational PurposesAn informational icon, calling your attention
      TIp
      Use of the following tool(s) is recommended:
      • 11 mm socket
    5. Repeat step 21.a through step 21.d to bleed the RH front caliper.
    6. Remove the RH rear caliper bleed valve cover, and then install the fluid catcher.
    7. Open the bleed valve and watch the fluid as it flows out of the caliper (~20 seconds).
    8. Close the bleed valve when clean fluid without bubbles flows out of the caliper.
    9. Remove the fluid catcher, and then torque the RH rear caliper bleed valve and install the valve cap.
      18.5 Nm (13.6 lbs-ft)
      Informational PurposesAn informational icon, calling your attention
      TIp
      Use of the following tool(s) is recommended:
      • 11 mm socket
    10. Repeat step 21.f through step 21.i to bleed the LH rear caliper.
  22. Turn off and remove the pressure brake bleeder kit from the vehicle.
  23. Check the brake fluid level and top off as necessary.
  24. Install the service brake reservoir cap.
  25. Remove the absorbent material from underneath the brake booster assembly and the reservoir area.
  26. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Chassis > Procedures > IDB Replacement > Bleed Internal Circuits, click Run, and allow the routine to complete.
  27. Tap Chassis > Procedures > IDB Replacement > Corner Stiffness Test, click Run, and allow the routine to complete.
  28. Tap Chassis > Procedures > IDB Replacement > Valve Test, click Run, and allow the routine to complete.
  29. Press the brake pedal several times to verify proper feel and action.
  30. Install all the four wheels. See Wheel Assembly (Remove and Install).
  31. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  32. Install the HEPA filter assembly. See SERVICE KIT - HEPA AND CARBON FILTERS (Remove and Replace).
  33. Disconnect the laptop. See Toolbox 3 (Connect and Disconnect).
  34. Exit Service Mode. See Service Mode.
  35. Raise the LH front window and close the LH front door.
  36. Remove the vehicle from the lift.
  37. Perform a road test to make sure there is proper pedal feel and brake performance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Add test drive correction code 00040100 as a separate activity to the Service Visit.