Brake Caliper - Rear

Complete replacement of the rear brake caliper on a 2022 Rivian EDV 500, including brake line disconnection, caliper removal, installation, and brake system bleeding.

Warnings

Tools required

Parts

• Rear brake caliper assembly × 1 — Use OEM Rivian specification
• Copper crush washers for banjo bolt × 2 — 14mm brake line copper washers
• Brake pads (if not included with caliper) × 1 — Use OEM Rivian specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake firmly
2. Chock the front wheels securely to prevent vehicle movement
3. Remove rear wheel center cap if equipped and loosen lug nuts 1/4 turn before lifting
4. Lift rear of vehicle using manufacturer-specified jacking points and support on jack stands rated for vehicle weight
5. Remove rear wheel completely
6. Open brake fluid reservoir cap slightly to allow fluid movement during caliper piston retraction
7. Have brake fluid collection pan ready beneath work area

Procedure

1. 1

   Prepare brake fluid reservoir
   Using a turkey baster or brake fluid syringe, remove approximately 1/3 of the brake fluid from the master cylinder reservoir to prevent overflow when retracting the caliper piston. Dispose of old fluid properly. Keep the reservoir cap loose but covered to prevent contamination.
2. 2

   Support the caliper
   Before disconnecting the brake line, prepare a wire hanger or bungee cord to support the caliper weight after removal. Do not allow the caliper to hang by the brake line as this can damage the line internally.
3. 3

   Disconnect brake line from caliper
   Place a drain pan under the caliper. Using a 15mm flare nut wrench, carefully loosen and remove the brake line banjo bolt from the rear of the caliper. Note the position of the copper crush washers (one on each side of the banjo fitting). Remove and discard both copper washers - new ones must be used during installation. Immediately plug the brake line opening with a rubber cap or clean shop towel to minimize fluid loss and contamination.
   ⚠Brake fluid will drain from the line. Have a collection pan positioned to catch fluid.
4. 4

   Remove caliper bracket bolts
   Locate the two caliper bracket bolts that secure the caliper assembly to the rear suspension knuckle. Using an 18mm socket and breaker bar, remove both caliper bracket bolts completely. These bolts are high-torque fasteners and may require significant force to break loose. Support the caliper as you remove the second bolt.
   ⚠Caliper assembly is heavy. Be prepared to support its weight as the second bolt is removed.
5. 5

   Remove caliper and bracket assembly
   Carefully lift the caliper and bracket assembly away from the rotor. Inspect the brake pads for wear and damage. If the caliper included new pads, remove the old pads from the bracket. Clean the bracket mounting surfaces with brake cleaner if reusing the bracket.
6. 6

   Inspect mounting surfaces and rotor
   With the caliper removed, inspect the brake rotor for excessive wear, scoring, or damage. Check the caliper mounting surface on the suspension knuckle for corrosion or debris. Clean mounting surfaces thoroughly with brake cleaner. Verify the rotor meets minimum thickness specifications if measuring equipment is available.
7. 7

   Prepare new caliper assembly
   Unpack the new caliper assembly. Verify it matches the removed caliper orientation (left or right rear). Remove any shipping plugs or protective covers from the bleeder screw and brake line port. If the caliper did not include new brake pads, transfer the pads to the new caliper bracket ensuring proper orientation with wear indicators positioned correctly.
8. 8

   Apply threadlocker to bracket bolts
   Clean the threads of both caliper bracket bolts with brake cleaner and allow to dry. Apply medium-strength threadlocker to the bolt threads according to threadlocker manufacturer instructions. This is critical for preventing bolt loosening under braking forces.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
9. 9

   Install new caliper assembly
   Position the new caliper and bracket assembly over the brake rotor, aligning the bracket bolt holes with the suspension knuckle mounting points. Start both caliper bracket bolts by hand to ensure proper thread engagement. Once both bolts are hand-tight, torque them in a cross pattern to specification using a calibrated torque wrench.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
10. 10

    Reconnect brake line with new washers
    Remove the plug from the brake line. Install one NEW copper crush washer onto the banjo bolt, then insert the bolt through the brake line banjo fitting. Place the second NEW copper washer on the opposite side, then thread the banjo bolt into the caliper body. Hand-tighten first to ensure proper alignment, then torque to specification using a torque wrench. Do not overtighten as this can damage the aluminum caliper body.
    ⚠Using old copper washers or exceeding specified torque can cause brake fluid leaks and brake system failure. Always use new washers and precise torque.
    Torque spec

    Brake Line Banjo Bolt25 Nm (18 lb-ft)
11. 11

    Bleed the rear brake caliper
    Attach a clear bleeding hose to the caliper bleeder screw and place the other end in a clean collection container with fresh DOT 4 brake fluid covering the hose end. Have an assistant slowly depress the brake pedal. Open the bleeder screw 1/4 turn using an 8mm wrench. Allow fluid and air to escape until the pedal reaches the floor. Close the bleeder screw before the assistant releases the pedal. Repeat this process until no air bubbles appear in the discharged fluid. Monitor the master cylinder reservoir constantly and refill as needed to prevent air entry.
    ⚠️Never allow the brake fluid reservoir to run empty during bleeding or air will enter the system requiring more extensive bleeding procedures.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
12. 12

    Final bleeder screw torque and inspection
    After bleeding is complete and no air bubbles are visible, close the bleeder screw with the brake pedal depressed. Torque the bleeder screw to specification - do not overtighten as the bleeder screw is brass and easily damaged. Wipe the caliper and surrounding area clean. Inspect the banjo bolt connection and bleeder screw for any signs of brake fluid leakage.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
13. 13

    Refill brake fluid reservoir and reinstall wheel
    Fill the brake fluid reservoir to the MAX line with fresh DOT 4 brake fluid. Securely reinstall the reservoir cap. Reinstall the rear wheel, hand-tighten all lug nuts in a star pattern, then lower the vehicle until the tire just contacts the ground. Torque lug nuts to manufacturer specification in a star pattern. Fully lower the vehicle and remove jack stands.

Reassembly

1. Ensure all brake line connections are tight and show no signs of leakage
2. Verify caliper bracket bolts are torqued to specification with threadlocker applied
3. Confirm brake fluid reservoir is filled to MAX line with fresh DOT 4 fluid
4. Verify wheel lug nuts are torqued to Rivian specification

Verification

• With vehicle still off, pump the brake pedal 10-15 times until firm resistance is felt. The pedal should become firm and not sink to the floor. If pedal remains soft, further bleeding is required
• Start the vehicle and verify the brake warning light is off on the instrument cluster
• Visually inspect the caliper, brake line connection, and bleeder screw for any fluid leakage
• Perform a low-speed brake test in a safe area (5-10 mph) to verify normal brake function before road use
• Perform a controlled stop from 30 mph in a safe area to verify proper brake response and absence of pulling
• After the test drive, recheck all connections for leakage and verify the brake pedal remains firm
• Check brake fluid level after test drive and top off if necessary
• Avoid aggressive braking for the first 50-100 miles to allow new pads to properly seat against the rotor

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