Brake Caliper - Front

Remove and replace the front brake caliper on a 2022 Rivian EDV 500, including bleeding the brake system and verifying proper operation.

Warnings

Tools required

Parts

• Front brake caliper assembly × 1 — Use OEM Rivian specification
• Brake line copper crush washers × 2 — Use OEM specification - 2 per banjo bolt
• Caliper bracket bolts (if corroded or damaged) × 2 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Open brake fluid reservoir and check fluid level - do not overfill during this procedure
4. Using floor jack, raise the front of vehicle at designated lift points per owner's manual
5. Secure vehicle on jack stands rated for at least 7,000 lbs
6. Remove front wheel on side being serviced
7. Verify caliper condition and confirm replacement is necessary
8. Have assistant available to monitor brake pedal during bleeding procedure

Procedure

1. 1

   Prepare brake fluid reservoir
   Using a turkey baster or fluid extraction pump, remove approximately 2-3 ounces of brake fluid from the master cylinder reservoir to prevent overflow when compressing the caliper piston. Dispose of old fluid properly - do not reuse.
2. 2

   Disconnect brake line from caliper
   Place a drip pan under the caliper. Using a 10mm flare nut wrench, carefully loosen and remove the brake line banjo bolt. Immediately plug the brake line with a rubber cap or tape to minimize fluid loss and prevent contamination. Remove and discard both copper crush washers from the banjo bolt - these must be replaced with new washers.
   ⚠Brake fluid will drain from the line. Have shop rags ready to catch fluid and prevent spills on components or ground.
3. 3

   Remove caliper bracket bolts
   Locate the two caliper bracket mounting bolts that secure the caliper assembly to the steering knuckle. Using an 18mm socket, break loose both bolts but do not fully remove yet. These bolts are torqued to 120 Nm and may require significant force to loosen. Support the caliper with one hand as you remove the second bolt completely.
   ⚠Caliper is heavy and may fall once bolts are removed. Maintain control of the assembly.
4. 4

   Remove old caliper
   With both bracket bolts removed, carefully lift the caliper assembly away from the rotor and steering knuckle. Inspect the mounting surfaces on the knuckle for corrosion, damage, or debris. Clean mounting surfaces with a wire brush if necessary. Set old caliper aside for core return if applicable.
5. 5

   Inspect brake rotor and pads
   With caliper removed, inspect the brake rotor for excessive wear, scoring, or damage. Check rotor thickness against manufacturer specifications. If replacing only the caliper and reusing existing pads, verify pad thickness is adequate (minimum 3mm). Clean rotor surface with brake cleaner if installing new caliper with new pads.
6. 6

   Prepare new caliper
   Unpack new caliper and verify it matches the old unit (driver or passenger side specific). If caliper pistons are not pre-compressed, use a C-clamp or brake piston tool to fully retract the pistons. Ensure bleeder screw moves freely - open slightly and close to verify. Remove any protective caps or plugs from brake line port.
   ℹ️Some replacement calipers come with brake pads pre-installed. Verify pad installation orientation before proceeding.
7. 7

   Install new caliper to knuckle
   Position the new caliper assembly over the brake rotor and align the mounting holes with the steering knuckle. If using threadlocker, apply a small amount to the caliper bracket bolt threads. Insert both bracket bolts and hand-thread them to ensure proper alignment. Using a torque wrench and 18mm socket, tighten both caliper bracket bolts in a cross pattern to the specified torque.
   ⚠️CRITICAL TORQUE: Caliper bracket bolts must be torqued to exactly 120 Nm (88 lb-ft). Under-torquing can cause caliper detachment and complete brake failure.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
8. 8

   Connect brake line to caliper
   Install one NEW copper crush washer on each side of the brake line banjo fitting. Position the banjo bolt through the brake line fitting and into the caliper port. Hand-thread the banjo bolt, ensuring the brake line is not twisted or kinked. Using a 10mm wrench and torque wrench, tighten the banjo bolt to the specified torque. Verify brake line has adequate clearance from wheel and suspension components through full steering travel.
   ⚠️CRITICAL: Always use NEW copper crush washers. Reusing old washers will cause brake fluid leaks and system failure. Torque to exactly 25 Nm (18 lb-ft).
   Torque spec

   Brake Line Banjo Bolt25 Nm (18 lb-ft)
9. 9

   Bleed brake caliper
   Attach a clear bleed tube to the caliper bleeder screw and place the other end in a catch bottle partially filled with clean DOT 4 brake fluid. Have an assistant sit in the driver's seat. Refill the brake fluid reservoir to the MAX line. Open the bleeder screw 1/4 turn with an 8mm wrench. Have assistant slowly depress brake pedal to the floor and hold. Close bleeder screw before assistant releases pedal. Repeat this process 5-10 times until no air bubbles appear in the bleed tube and fluid flows clear. Close bleeder screw to specified torque on final compression.
   ⚠️Monitor brake fluid reservoir constantly during bleeding. Never allow reservoir to run empty or air will enter the ABS system, requiring specialized equipment to bleed.
   ⚠Ensure bleeder screw is closed before assistant releases brake pedal, or air will be drawn back into the system.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
10. 10

    Verify brake pedal and check for leaks
    With engine off (on EVs, vehicle in accessory mode), pump brake pedal 10-15 times. Pedal should become firm and hold pressure. If pedal remains soft or sinks to floor, repeat bleeding procedure. Inspect the banjo bolt connection and bleeder screw for any signs of brake fluid leakage. Wipe all connections dry and observe for 2-3 minutes. Top off brake fluid reservoir to proper level between MIN and MAX marks.
    ⚠️A soft or sinking brake pedal indicates air in the system or a fluid leak. DO NOT drive the vehicle until pedal is firm and holds pressure.
11. 11

    Reinstall wheel and perform final checks
    Clean wheel mounting surface on hub. Install wheel and hand-thread all lug nuts. Lower vehicle until tire just contacts ground. Torque lug nuts to manufacturer specification (typically 150-180 Nm for Rivian EDV) in a star pattern. Fully lower vehicle and remove jack stands. Pump brake pedal several times to ensure proper caliper piston position. Check brake fluid level one final time and add DOT 4 fluid if needed.

Reassembly

1. Ensure all brake line connections are secure and free of leaks
2. Verify caliper bracket bolts are torqued to 120 Nm and secure
3. Confirm brake fluid reservoir is filled to proper level with DOT 4 fluid
4. Double-check that bleeder screw is closed to 10 Nm and not leaking
5. Verify wheel lug nuts are properly torqued in star pattern

Verification

• Start vehicle and test brake pedal feel - should be firm with no excessive travel
• Perform a low-speed brake test (5-10 mph) in a safe area to verify braking function
• Check for any unusual noises, vibrations, or pulling to one side during braking
• Inspect caliper area for any signs of brake fluid leakage after test drive
• Verify brake warning lights are not illuminated on instrument cluster
• Perform several moderate stops from 25-30 mph to bed in new caliper/pads if applicable
• Re-check brake fluid level after test drive and top off if necessary
• CRITICAL: If brake pedal is soft, vehicle pulls during braking, or any warning lights appear, DO NOT drive vehicle - have it towed to a qualified technician

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