Brake Pads - Front

Replacement of front brake pads on a 2022 Rivian EDV 500 electric delivery van, including caliper service and proper bedding procedures.

Warnings

Tools required

Parts

• Front brake pad set (4 pads total) × 1 — Use OEM Rivian specification
• Brake pad anti-rattle clips × 1 — Usually included with pad set
• Brake hardware spring kit × 1 — Usually included with pad set

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground. Place wheel chocks behind rear wheels.
2. Ensure vehicle is in Park mode and ignition is OFF.
3. Open hood and disconnect 12V negative battery terminal to disable all electrical systems including regenerative braking.
4. Remove reservoir cap from brake fluid reservoir and extract approximately 2 ounces of fluid with turkey baster (to prevent overflow when compressing pistons).
5. Loosen front wheel lug nuts 1/4 turn while vehicle is still on ground.
6. Raise front of vehicle with floor jack at designated front jacking point and secure with jack stands under frame rails.
7. Remove front wheels completely and set aside.

Procedure

1. 1

   Inspect brake system condition
   Before disassembly, inspect brake rotors for scoring, cracks, or excessive wear. Check brake hoses for cracks or leaks. Measure rotor thickness with micrometer if available (minimum thickness is typically stamped on rotor hat). Inspect caliper for fluid leaks around piston boots. If rotors are damaged or below minimum thickness, they must be replaced before installing new pads.
2. 2

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper assembly. These are typically 15mm bolts. Using appropriate socket, remove both upper and lower slide pin bolts. Support the caliper with your hand as you remove the second bolt to prevent it from falling. The caliper should now pivot away from the rotor.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Remove caliper from rotor
   Carefully lift the caliper assembly off the rotor and brake pad assembly. Do NOT let the caliper hang by the brake hose as this can damage the hose internally. Use a bungee cord or wire to suspend the caliper from the suspension component or frame, keeping tension off the brake hose. Ensure adequate clearance for the brake hose with no kinks or sharp bends.
4. 4

   Remove old brake pads and hardware
   Remove the outer and inner brake pads from the caliper bracket. Note the orientation and position of any anti-rattle clips, shims, or springs for reinstallation. Remove all pad hardware including clips and springs. Inspect the caliper bracket for any damage or excessive wear on the pad slides.
5. 5

   Clean caliper bracket and slides
   Using a wire brush, thoroughly clean the brake pad slide areas on the caliper bracket where the pad ears contact. Remove all rust, old grease, and debris. Clean the caliper slide pins by removing them from the bracket and wiping clean. Inspect slide pin boots for tears or damage - replace if compromised. Clean the rotor surface with brake cleaner and wipe with clean cloth.
6. 6

   Compress caliper piston
   Using a C-clamp or brake caliper piston compression tool, slowly compress the caliper piston(s) fully into the caliper bore. Place the clamp against the piston face and the back of the caliper body. Compress slowly and steadily. Monitor the brake fluid reservoir - it should rise but not overflow. If fluid level gets too high, remove more fluid with turkey baster. Ensure piston compresses evenly and fully seats.
7. 7

   Lubricate and install new hardware
   Apply a thin layer of silicone brake grease to the caliper slide pins (not petroleum-based grease). Reinstall slide pins into caliper bracket with new boots if needed. Apply thin layer of silicone brake grease to the brake pad slide contact points on the caliper bracket where pad ears will sit. Install new anti-rattle clips and springs in the same orientation as removed. Do NOT apply grease to pad friction material or rotor surface.
8. 8

   Install new brake pads
   Install new inner and outer brake pads into the caliper bracket, ensuring they are properly seated in the anti-rattle clips. Verify the pad wear indicators (if equipped) are positioned correctly according to manufacturer specification (typically on the inner pad, pointing in direction of rotation). Ensure pads move freely in the bracket but are retained by clips.
9. 9

   Reinstall caliper assembly
   Remove the caliper from its suspended position. Carefully position the caliper over the new brake pads and rotor, ensuring brake hose is not twisted. Align caliper mounting holes with bracket. Clean caliper slide pin bolt threads with brake cleaner. Apply medium-strength threadlocker to slide pin bolt threads as specified. Install both slide pin bolts and hand-tighten initially, then torque to specification.
   ⚠Ensure brake hose has adequate slack and is not twisted or kinked when caliper is reinstalled.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Repeat procedure for opposite side
    Perform steps 1 through 9 on the opposite front brake assembly. It is critical to replace brake pads on both front wheels simultaneously to maintain balanced braking performance. Never replace pads on only one side of an axle.
11. 11

    Reinstall wheels and torque lug nuts
    Clean wheel mounting surface on hub with wire brush. Reinstall both front wheels, starting lug nuts by hand to ensure proper thread engagement. Using star/cross pattern, tighten lug nuts progressively in multiple passes. Final torque all lug nuts to specification using calibrated torque wrench in star pattern.
    ⚠️Improperly torqued wheel lug nuts can cause wheel detachment while driving. Always use calibrated torque wrench and star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
12. 12

    Check brake fluid level and bleed if necessary
    Check brake fluid level in reservoir. Add DOT 4 brake fluid to bring level to MAX line if needed. Do not overfill. If brake pedal feels spongy after reassembly, brake system may need bleeding - this requires two people or a pressure bleeder. Reinstall reservoir cap securely. Reconnect 12V battery negative terminal.
13. 13

    Pump brake pedal and verify operation
    With vehicle still elevated on jack stands, sit in driver's seat and pump brake pedal 10-15 times until pedal feels firm and normal height is restored. Pedal should become progressively firmer and reach normal position. If pedal remains soft or goes to floor, do NOT drive vehicle - system requires bleeding. Check under vehicle for any brake fluid leaks at calipers and hoses.
14. 14

    Lower vehicle and perform final checks
    Carefully lower vehicle from jack stands using floor jack. Once vehicle is on ground, perform final torque check on all wheel lug nuts in star pattern to specification. Remove jack and jack stands. Test brake pedal feel with engine off - should be firm with normal travel.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. All fasteners must be torqued to specification using calibrated torque wrench.
2. Wheel lug nuts must be torqued in star pattern in multiple progressive passes.
3. Caliper bracket bolts require threadlocker application before installation.
4. Brake fluid level must be at MAX line with reservoir cap properly sealed.
5. 12V battery negative terminal must be reconnected and secured.

Verification

• With vehicle on ground and brake pedal pumped, pedal should feel firm at normal height with approximately 1-2 inches of travel before resistance.
• Start vehicle and verify brake warning light is OFF on instrument cluster.
• Perform low-speed test drive in safe area (parking lot). Test brakes at 5-10 mph to verify proper engagement. Braking should be smooth with no pulling to either side.
• Perform 30-50 controlled stops from 30 mph with moderate braking pressure to bed-in new pads (allow 30 seconds between stops for cooling).
• After bedding procedure, perform final brake check from 40 mph in safe area. Braking should be firm, straight, and progressive with no noise, vibration, or pulling.
• Recheck wheel lug nut torque after first 50 miles of driving.
• Monitor brake pedal feel for first 200 miles. If pedal becomes soft or brake warning light illuminates, have system inspected immediately.
• Be aware that full brake performance may not be achieved until pads are fully bedded (approximately 200-300 miles of mixed driving).

More procedures for this vehicle