my Tesla Model S Original (2012-2020) has a weird smell when I use the brakes

Tesla Model S Plaid/Refresh (2021-present)

Error Codes

2-4 hours

Time

medium

Difficulty

high

Severity

3 min read

488 words

⚠️ Safety Warning

This issue requires immediate attention. If you are not experienced with automotive repairs, consult a professional mechanic. Working on critical systems can be dangerous.

Problem Statement

Learn how to diagnose and fix the burning smell when braking in Tesla Model S (2012-2020). Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Affected Component

Brakes

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Ensure the vehicle is securely lifted and supported before working underneath.
•Always allow brakes to cool down before inspection or repairs.

Symptoms

•Burning smell when brakes are applied
•Reduced braking effectiveness
•Brake pedal feels spongy or unresponsive
•Possible warning lights illuminated on the dashboard (e.g., brake system warning)
•Squeaking or grinding noise when braking

Diagnostic Steps

1
Inspect brake pads for wear and damage.
2
Check brake fluid level and condition.
3
Examine brake calipers for leaks or sticking components.
4
Inspect brake rotors for scoring or warping.
5
Scan for any diagnostic trouble codes (DTCs) related to the braking system.

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•Lug wrench
•Brake fluid tester (optional)
•Wrench set
•Brake cleaner
•Dial indicator
•Rotor removal tool

Parts Required

•Brake pads
•Brake fluid (DOT 3 or DOT 4)
•Brake rotors (if needed)

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Solution

1. Preparation

Gather necessary tools and safety equipment.
Ensure the vehicle is parked on a level surface and the parking brake is engaged.
Wear safety goggles and gloves.

2. Inspect Brake Pads

Sub-steps:
- Remove the wheel using a lug wrench.
- Inspect brake pads for thickness. Replace if less than 3mm.
- Check for uneven wear or cracks in the pads.
Tools Required: Lug wrench

3. Check Brake Fluid

Sub-steps:
- Locate the brake fluid reservoir under the hood.
- Inspect the fluid level; it should be between the MIN and MAX marks.
- Check the fluid color; if dark or contaminated, flush the system and replace with fresh brake fluid (DOT 3 or DOT 4).
Tools Required: Brake fluid tester (optional)

4. Examine Brake Calipers

Sub-steps:
- Inspect calipers for leaks or corrosion.
- Check that caliper pistons move freely; apply brake cleaner and lubricate if necessary.
- Ensure the caliper mounting bolts are properly torqued.
Tools Required: Wrench set, brake cleaner

5. Inspect Rotors

Sub-steps:
- Use a dial indicator to check rotor runout for warping.
- Inspect for scoring or surface cracks.
- If warped or damaged, replace rotors with OEM or equivalent parts.
Tools Required: Dial indicator, rotor removal tool