This procedure covers the removal and replacement of the brake caliper bracket on a 2022 Rivian EDV 500. This is a safety-critical brake system repair that requires proper torque specifications and brake system bleeding.

Warnings

Tools required

Parts

• Brake caliper bracket × 1 — Use OEM specification
• Caliper bracket mounting bolts × 2 — Use OEM specification
• Brake pads (if damaged) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid surface and engage parking brake (or apply wheel chocks to opposite wheels if working on rear brakes)
2. Place vehicle in service/transport mode per owner's manual to disable regenerative braking and high voltage systems
3. Loosen wheel lug nuts while vehicle is on ground
4. Raise vehicle with floor jack at designated lift point and secure with jack stands rated for vehicle weight
5. Remove wheel completely
6. Inspect brake system for additional damage or wear that may need attention
7. Clean wheel hub and brake assembly area with brake cleaner to remove road debris

Procedure

1. 1

   Disconnect brake wear sensor if equipped
   Locate the brake pad wear sensor connector on the caliper or bracket. Press the release tab and carefully disconnect the electrical connector. Note the routing of the wire for reinstallation.
2. 2

   Remove brake caliper
   Remove the two caliper mounting bolts (typically on the back side of the caliper). These are separate from the bracket bolts. Carefully lift the caliper off the bracket. DO NOT allow the caliper to hang by the brake hose. Support the caliper using a brake caliper hanger or secure it to the suspension with wire to prevent strain on the brake line.
   ⚠Never allow the brake caliper to hang unsupported by the brake hose. This can damage the hose internally and cause brake failure.
3. 3

   Remove brake pads and hardware
   Remove the brake pads from the caliper bracket. Remove any anti-rattle clips, shims, or pad retention hardware attached to the bracket. Keep track of all hardware for reinstallation. Inspect brake pads for uneven wear which may indicate other issues.
4. 4

   Remove caliper bracket mounting bolts
   Locate the two large caliper bracket mounting bolts that secure the bracket to the steering knuckle or axle hub. These bolts are typically larger than the caliper mounting bolts. Use the appropriate socket and breaker bar to remove both bolts. These bolts are often very tight and may require significant force. Keep track of any washers or spacers.
   ⚠Caliper bracket bolts are high-torque fasteners. Use proper size tools to avoid rounding bolt heads. Apply penetrating oil if bolts are corroded.
5. 5

   Remove caliper bracket
   With both mounting bolts removed, carefully slide the caliper bracket off the rotor and away from the mounting surface. If the bracket is stuck, gently tap with a rubber mallet. Do not strike the rotor.
6. 6

   Inspect mounting surfaces and rotor
   With the bracket removed, thoroughly inspect the brake rotor for scoring, heat damage, or excessive wear. Check rotor thickness against specifications if replacement is being considered. Clean the mounting surface on the knuckle or hub with a wire brush to remove rust and debris. Inspect the bolt holes for damage or stripped threads.
7. 7

   Prepare new caliper bracket
   Unpack the new caliper bracket and verify it matches the original. Clean all mounting surfaces. Apply a thin layer of anti-seize compound to the mounting bolt threads (not to the bolt heads or mounting surfaces). Install any hardware that came pre-attached to the bracket.
   ℹ️Verify the new bracket is the correct part for your specific wheel position (front left, front right, etc.) as brackets may differ between positions.
8. 8

   Install new caliper bracket
   Position the new caliper bracket over the brake rotor and align the mounting bolt holes with the knuckle or hub. Start both mounting bolts by hand to ensure proper thread engagement. DO NOT FULLY TIGHTEN YET.
   ⚠CRITICAL: This procedure cannot be completed safely without manufacturer torque specifications. The caliper bracket bolts must be torqued to exact specifications. Contact Rivian service or consult a professional technician to obtain proper torque values before proceeding.
9. 9

   Torque caliper bracket mounting bolts
   Using a calibrated torque wrench, tighten the caliper bracket mounting bolts in a cross pattern (if applicable) to the manufacturer's specified torque value. Since no torque specification is available in this database, you MUST obtain the correct value from Rivian service documentation before completing this step. Typical values for this class of vehicle range from 125-180 ft-lbs, but you must verify the exact specification.
   ⚠️DO NOT GUESS at torque values. Under-torqued bolts can allow the bracket to separate during braking, causing total brake failure. Over-torquing can strip threads or break bolts. Obtain verified torque specifications before proceeding.
10. 10

    Reinstall brake pad hardware and pads
    Install all anti-rattle clips, shims, and pad retention hardware to the new bracket in the same configuration as removed. Install the brake pads, ensuring the friction material faces the rotor and pads are properly seated in the bracket. If installing new brake pads, ensure they are the correct specification for your vehicle.
11. 11

    Reinstall brake caliper
    Remove the caliper from its support. If brake pads were replaced, compress the caliper piston(s) back into the caliper bore using a caliper compression tool. This may cause brake fluid to rise in the master cylinder reservoir. Position the caliper over the brake pads and bracket. Install the caliper mounting bolts and tighten to manufacturer specification. Again, obtain the proper torque value from Rivian service documentation.
12. 12

    Reconnect brake wear sensor
    Reconnect the brake pad wear sensor electrical connector if equipped. Ensure the connector clicks into place and the wire is routed properly away from rotating components and heat sources. Secure any wire clips.
13. 13

    Bleed brake system
    The brake system must be bled after caliper bracket replacement. Check the brake fluid reservoir and top off with fresh DOT 4 brake fluid if needed. Use a brake bleeding kit to bleed air from the affected brake circuit following proper bleeding sequence (typically furthest wheel from master cylinder first). Continue until no air bubbles appear in the discharged fluid. Maintain proper fluid level in reservoir throughout bleeding process.
    ⚠️Air in the brake system will cause brake failure. The system MUST be properly bled before returning the vehicle to service. If you are not experienced with brake bleeding procedures, seek professional assistance.

Reassembly

1. Reinstall the wheel and hand-tighten all lug nuts in a star pattern
2. Lower the vehicle until the tire just touches the ground (weight on wheel but still supported by jack stands)
3. Torque wheel lug nuts to specification in a star pattern (consult owner's manual for exact torque)
4. Fully lower vehicle and remove jack stands
5. Pump brake pedal several times until it feels firm before moving vehicle
6. Top off brake fluid reservoir to MAX line with fresh DOT 4 brake fluid
7. Exit service/transport mode and restore vehicle to normal operation

Verification

• Before moving vehicle, pump brake pedal multiple times. Pedal must become firm and hold pressure. If pedal sinks slowly or goes to floor, DO NOT DRIVE - recheck installation and bleed system again
• Check for any brake fluid leaks around the caliper, bracket, and brake line connections
• Verify brake pad wear sensor connector is secure and warning light is not illuminated on dashboard
• Perform a low-speed brake test in a safe area (empty parking lot) at 5-10 mph to verify proper brake function
• Check for any unusual noises, vibrations, or pulling to one side during braking
• Perform a higher-speed brake test (25-30 mph) in a safe area to confirm proper stopping power
• Recheck wheel lug nut torque after driving 50-100 miles
• Monitor brake pedal feel and stopping performance for the first several trips. If anything feels abnormal, have the system inspected immediately by a professional
• Verify brake fluid level after test drive and top off if necessary

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