2024-05-29

Master Cylinder and Reservoir Assembly (Remove and Replace)

Correction code 33201012 1.32 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2023-12-07: Updated brake stiffness routine.
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Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

  1. Open LH front door
  2. Lower LH front window
  3. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure vehicle is not charging before lifting it off the ground, Set air suspension to "Jack Mode" if equipped
  4. Open hood
  5. Remove rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  6. Remove access panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x connector
  7. Remove fasteners securing the frunk assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, 10mm, 5 Nm, Newer vehicles may be equipped with 1x push clip securing frunk to reservoir neck
  8. Remove frunk assembly from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, Replace any clips if broken or missing
  9. Remove all four wheels. See Wheel Assembly (Remove and Install).
  10. Lower vehicle partially and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  11. Power off vehicle from center display
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    Note
    Via Controls > Safety & Security > Vehicle Power > Power Off
  12. Disconnect 12V negative terminal and first responders loop
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, 1x connector, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V, Negative terminal should be disconnected before FRL, Allow 2 minutes for all electrical circuits to fully discharge
  13. Remove LH wiper arm nut cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  14. Remove the nut securing the LH wiper arm to wiper module
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 15mm, 25 Nm
  15. Disconnect washer hose from LH wiper arm to Y-tube fitting and release washer hose clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x hose
  16. Remove the LH wiper arm and hose assembly from vehicle
  17. Remove RH wiper arm nut cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  18. Remove the nut securing the RH wiper arm to wiper module
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 15mm, 25 Nm
  19. Disconnect washer hose from RH wiper arm to Y-tube fitting and release washer hose clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x hose
  20. Remove the RH wiper arm and hose assembly from vehicle
  21. Disconnect washer hose from washer pump to Y-tube fitting and release washer hose clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x hose
  22. Remove cowl screen retaining clips
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips
  23. Release the cowl clips at the center bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x retaining clips
  24. Remove cowl screen from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Release the corners of the cowl by pulling away from the body then lift the cowl off of the windshield
  25. Disconnect brake fluid reservoir
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Slide locking tab away from connector to fully release
  26. Place absorbent material underneath brake booster and reservoir area
  27. Clean area around brake fluid reservoir and remove brake reservoir cap
  28. Remove fluid from brake fluid reservoir
  29. Install brake reservoir cap
  30. Disconnect forward brake line from master cylinder
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  31. Disconnect rear brake line from master cylinder
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  32. Remove nuts securing brake master cylinder to brake booster
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    Note
    2x nuts, 13mm, 20 Nm
  33. Remove brake master cylinder from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the o-ring come off with brake master

Install

  1. Install brake master cylinder to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure i-booster rod is aligned with brake master cylinder during installation
  2. Install nuts securing brake master cylinder to brake booster
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 13mm, 20 Nm
  3. Connect rear brake line into master cylinder
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  4. Connect forward brake line into master cylinder
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  5. Remove absorbent material from underneath brake booster assembly and reservoir area
  6. Connect brake fluid reservoir connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Secure locking tab by sliding towards connector once installed
  7. Install cowl screen assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Press the corners of the cowl into the body
  8. Install the cowl clips at the center bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x retaining clips
  9. Install cowl screen retaining clips
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  10. Connect washer hose from washer pump to Y-tube fitting and secure washer hose clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x hose
  11. Install the RH wiper arm and hose assembly onto vehicle
  12. Install the nut securing the RH wiper arm to wiper module
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 15mm, 25 Nm, Make sure the wiper tip is aligned between the two indicators at corner of windshield
  13. Install RH wiper arm nut cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  14. Connect washer hose from RH wiper arm to Y-tube fitting and secure washer hose clips
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x hose
  15. Install the LH wiper arm and hose assembly onto vehicle
  16. Install the nut securing the LH wiper arm to wiper module
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 15mm, 25 Nm, Make sure the wiper tip is aligned between the two indicators at windshield
  17. Install LH wiper arm nut cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  18. Connect washer hose from LH wiper arm to Y-tube fitting and secure washer hose clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x hose
  19. Fill brake bleeder reservoir to full level
  20. Clean area around brake fluid reservoir and remove brake reservoir cap
  21. Top off brake fluid reservoir
    Informational PurposesAn informational icon, calling your attention
    Note
    Top off brake fluid as needed
  22. Install pressure bleeder adapter onto reservoir
  23. Set brake bleed reservoir pressure to 30 psi
    Informational PurposesAn informational icon, calling your attention
    Note
    Connect power supply to bleeder and turn on the power, Set pressure to 30 psi, Attach brake bleed reservoir to brake bleed adapter
  24. Connect to vehicle using Toolbox 3.0
  25. Select Actions/Autodiag and search for "bleed"
  26. Remove bleeding valve covers and install the fluid catching bottle to LH front brake caliper outer bleeding valve before starting the ESP
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers
  27. Open LH front brake caliper outer bleeding valve then click the play button next to PROC_ESP_FRONT-L-REAR-R-BRAKE-BLEEDvia Toolbox: (link)via Service Mode: Chassis ➜ Brakes ➜ Brake Bleed FL-RRvia Service Mode Plus:
    • chassis ➜ ESP Post Replacement ➜ Bleed FL/RR Calipers
    • chassis ➜ ESP Replacement Panel ➜ Bleed FL/RR Calipers
    • chassis ➜ IBST Replacement Panel ➜ Bleed FL/RR Calipers
     and select Run to start the ESP, then close the bleeding valve once the pump stop running, then repeat the process for inner bleeding valve, and then lastly repeat the process for outer bleeding valve again
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  28. Repeat the above step till clear fluid and no air bubbles come out of the LH front brake caliper bleeding valve
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  29. Remove the fluid catching bottle, Torque LH front brake caliper bleeding valves then install covers
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  30. Remove bleeding valve covers and install the fluid catching bottle to RH front brake caliper outer bleeding valve before starting the ESP
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers
  31. Open RH front brake caliper outer bleeding valve then Click the play button next to PROC_ESP_FRONT-R-REAR-L-BRAKE-BLEEDvia Toolbox: (link)via Service Mode: Chassis ➜ Brakes ➜ Brake Bleed FR-RLvia Service Mode Plus:
    • chassis ➜ ESP Post Replacement ➜ Bleed FR/RL Calipers
    • chassis ➜ ESP Replacement Panel ➜ Bleed FR/RL Calipers
    • chassis ➜ IBST Replacement Panel ➜ Bleed FR/RL Calipers
     and select Run to start the ESP, then close the bleeding valve once the pump stop running, then repeat the process for inner bleeding valve, and then lastly repeat the process for outer bleeding valve again
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  32. Repeat the above step till clear fluid and no air bubbles come out of the RH front brake caliper bleeding valves
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  33. Remove the fluid catching bottle, Torque RH front brake caliper bleeding valves and install covers
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  34. Remove bleeding valve cover and install the fluid catching bottle to RH rear brake caliper bleeding valve before starting the ESP
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  35. Open RH rear brake caliper bleeding valve then Click the play button next to PROC_ESP_FRONT-L-REAR-R-BRAKE-BLEEDvia Toolbox: (link)via Service Mode: Chassis ➜ Brakes ➜ Brake Bleed FL-RRvia Service Mode Plus:
    • chassis ➜ ESP Post Replacement ➜ Bleed FL/RR Calipers
    • chassis ➜ ESP Replacement Panel ➜ Bleed FL/RR Calipers
    • chassis ➜ IBST Replacement Panel ➜ Bleed FL/RR Calipers
     and select Run to start the ESP, then close the bleeding valve once the pump stop running
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  36. Repeat the above step till clear fluid and no air bubbles come out of the RH rear brake caliper bleeding valve
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  37. Remove the fluid catching bottle, Torque RH rear brake caliper bleeding valve and install cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  38. Remove bleeding valve cover and install the fluid catching bottle to LH rear brake caliper bleeding valve before starting the ESP
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  39. Open LH rear brake caliper bleeding valve then Click the play button next to PROC_ESP_FRONT-R-REAR-L-BRAKE-BLEEDvia Toolbox: (link)via Service Mode: Chassis ➜ Brakes ➜ Brake Bleed FR-RLvia Service Mode Plus:
    • chassis ➜ ESP Post Replacement ➜ Bleed FR/RL Calipers
    • chassis ➜ ESP Replacement Panel ➜ Bleed FR/RL Calipers
    • chassis ➜ IBST Replacement Panel ➜ Bleed FR/RL Calipers
     and select Run to start the ESP, then close the bleeding valve once the pump stop running
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  40. Repeat the above step untill clear fluid and no air bubbles come out of the LH rear brake caliper bleeding valve
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  41. Remove the fluid catching bottle, Torque LH rear brake caliper bleeding valve and install cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  42. Power off brake bleed reservoir and detach brake bleed reservoir from brake bleed adapter
  43. Remove pressure bleeder adapter from reservoir
  44. Check fluid level
    Informational PurposesAn informational icon, calling your attention
    Note
    Top off if necessary
  45. Install brake reservoir cap
  46. Pump the brake pedal a few times to ensure the brake pedal feels normal
  47. Using Toolbox 3:
    1. Select the Actions tab and search for "Stiffness".
    2. Select the ODIN routine TEST_BRAKE_X_STIFFNESS-TEST-SERVICEvia Toolbox: (link)via Service Mode: Chassis ➜ Brakes ➜ Brake Stiffness Test, and then click the link of the routine.
    3. If brake pads or rotors have been replaced, select UNBURNISHED under "Action_Type". In all other cases, select BURNISHED.
    4. Click RUN, and allow the routine to complete.
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      Note
      Do not press the brake pedal during the test.
  48. Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
  49. Raise vehicle partially and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to a comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  50. Install all wheels. See Wheel Assembly (Remove and Install).
  51. Install rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
  52. Close hood
  53. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
  54. Raise LH front window
  55. Close LH front door
  56. Perform test drive
    Informational PurposesAn informational icon, calling your attention
    Note
    Per current FRT (00040100) 0.3 hrs, If alignment was adjusted verify tracking, If DAS components were adjusted verify operation, If brakes were serviced perform burnishing