Brake Pads and Rotors - Front

This procedure covers the removal and replacement of front brake pads and rotors on a 2022 Rivian EDV 500 electric delivery vehicle, including proper bedding-in procedures for the regenerative braking system.

Warnings

Tools required

Parts

• Front brake pad set × 1 — Use OEM Rivian specification
• Front brake rotors × 2 — Use OEM Rivian specification
• Brake hardware kit (clips, anti-rattle springs) × 1 — Use OEM Rivian specification
• Brake caliper bolts (if corroded) × 4 — Use OEM Rivian specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, stable surface and set parking brake
2. Disable regenerative braking if option is available in vehicle settings to prevent unexpected motor engagement
3. Using a turkey baster or brake fluid syringe, remove approximately 1/3 of brake fluid from master cylinder reservoir to prevent overflow when retracting caliper pistons
4. Loosen front wheel lug nuts 1/4 turn while vehicle is still on ground
5. Raise front of vehicle using appropriate lift points (consult owner's manual for EDV jack points)
6. Support vehicle on jack stands rated for minimum 7000 lbs, positioned at manufacturer-specified support points
7. Remove both front wheels completely
8. Verify vehicle is stable before working underneath

Procedure

1. 1

   Inspect brake system and document initial condition
   Before disassembly, inspect brake components for uneven wear patterns, fluid leaks at caliper seals, damaged brake lines, and condition of rubber boots. Check rotor thickness and document measurements. Take photos of brake pad wear and hardware orientation for reference during reassembly. This is especially important on the EDV as regenerative braking may cause unusual wear patterns.
2. 2

   Remove brake caliper
   Locate the two caliper mounting bolts on the rear of the caliper (typically 18mm). Remove the lower caliper bolt first, then the upper bolt. Carefully pivot the caliper upward off the rotor. Do NOT let the caliper hang by the brake hose. Support the caliper using a bungee cord or wire hooked to the suspension or frame. Never allow tension on the brake hose as this can cause internal damage and brake failure.
   ⚠Support the caliper weight immediately after removing the second bolt. The caliper weighs approximately 10-15 lbs and can damage the brake hose if allowed to hang freely.
3. 3

   Remove old brake pads and hardware
   With the caliper supported, slide out the old brake pads from the caliper bracket. Remove any anti-rattle clips, shims, or spring hardware from the caliper bracket. Take note of the orientation of all hardware components. Inspect the caliper bracket for wear grooves where the pad tabs slide. Clean the bracket thoroughly with brake parts cleaner and a wire brush, removing all rust and debris from pad contact surfaces.
4. 4

   Remove brake rotor
   If present, remove any rotor retaining screws (typically T30 or T40 Torx). These may be corroded and require penetrating oil. Once screws are removed, pull the rotor straight off the hub. If the rotor is stuck due to corrosion, tap gently around the perimeter with a rubber mallet. Do NOT strike the rotor face as this can cause cracking. If severely stuck, use rotor puller bolts threaded into the provided holes on the rotor face.
5. 5

   Clean and inspect wheel hub
   With the rotor removed, thoroughly clean the wheel hub face with a wire brush, removing all rust, scale, and corrosion. The hub surface must be completely clean and flat to prevent rotor runout, which causes vibration and uneven pad wear. Inspect the wheel bearing for play or noise by attempting to rock the hub. Any looseness indicates bearing issues that must be addressed before installing new brakes. Clean the hub pilot diameter where the rotor centers.
6. 6

   Install new brake rotor
   Remove any protective coating from the new rotor using brake parts cleaner. Spray both sides thoroughly and wipe clean with lint-free cloth. Slide the new rotor onto the hub, ensuring it seats fully against the hub face. Install rotor retaining screws if equipped and tighten firmly (hand tight plus 1/4 turn). These screws only hold the rotor during assembly and are not structural. Verify the rotor spins freely without rubbing or scraping.
7. 7

   Retract caliper pistons
   Using a brake caliper wind-back tool or large C-clamp, slowly retract the caliper pistons fully into the caliper bore. Position the tool against the back of the piston (not against the brake pad if still in place). Apply gradual, even pressure. As the piston retracts, brake fluid will be pushed back into the master cylinder reservoir. Monitor the reservoir and remove excess fluid if necessary to prevent overflow. For Rivian EDV with electronic brake system, you may need to use a diagnostic scan tool to activate service mode before pistons can be fully retracted.
   ⚠Some Rivian vehicles require electronic brake service mode to be activated before caliper pistons can be retracted. Consult vehicle service information if pistons resist retraction.
8. 8

   Install new brake pad hardware and pads
   Install new anti-rattle clips and any shims included with the brake pad set into the caliper bracket, matching the orientation documented during disassembly. Apply a thin film of high-temperature brake lubricant to the pad backing plate contact points on the bracket (do NOT apply lubricant to friction surfaces). Install the new brake pads into the caliper bracket, ensuring the friction material faces the rotor. Verify pads slide smoothly in the bracket without binding.
9. 9

   Reinstall brake caliper
   Carefully lower the caliper over the new pads and rotor. Align the caliper mounting holes with the bracket or knuckle. Install both caliper mounting bolts and hand-tighten. Torque the caliper bolts to manufacturer specification in a cross pattern. NOTE: Specific torque values for the 2022 Rivian EDV 500 are not available in the current database. Consult the Rivian service manual or contact Rivian technical support for proper torque specifications before final tightening. Typical values for similar vehicles range from 70-100 ft-lbs, but do NOT assume this without verification.
   ⚠️Improperly torqued caliper bolts can cause caliper detachment during braking, resulting in complete brake failure. Do NOT proceed without obtaining verified torque specifications for this vehicle.
10. 10

    Repeat process for opposite side
    Perform steps 1 through 9 for the opposite front brake assembly. Always replace brake pads and rotors in axle sets (both front wheels) to maintain balanced braking performance. Never replace only one side, as this creates uneven braking forces that can cause vehicle pull and instability during braking.

Reassembly

1. Reinstall both front wheels, starting lug nuts by hand to prevent cross-threading
2. Lower vehicle until wheels just contact ground but vehicle weight is still on jack stands
3. Torque wheel lug nuts to manufacturer specification in a star pattern (specification not available in database - consult Rivian service manual)
4. Fully lower vehicle and remove jack stands
5. Perform final torque verification of all lug nuts with vehicle weight on wheels

Verification

• Before starting vehicle, pump brake pedal slowly 10-15 times until pedal becomes firm. Pedal should not travel more than halfway to floor. If pedal remains soft, there may be air in the system or improperly installed components.
• Check brake fluid level in master cylinder reservoir and top off with DOT 4 brake fluid to MAX line if needed
• Start vehicle and verify no brake warning lights are illuminated on instrument cluster. If warning lights appear, use diagnostic scanner to check for fault codes
• With vehicle running, press brake pedal firmly and verify it holds position without sinking. Any pedal sink indicates a leak or air in the system
• Perform low-speed brake test in safe area: Drive at 5-10 mph and apply brakes gently. Vehicle should stop smoothly without pulling to either side or making unusual noises
• Perform brake bedding-in procedure: Make 10-15 stops from 30 mph with moderate brake pressure, allowing 30 seconds between stops to cool brakes. Avoid aggressive stops during first 200 miles
• After bedding-in, verify no brake warning lights have appeared and brake pedal remains firm
• Re-torque wheel lug nuts after 50 miles of driving
• If regenerative braking was disabled, re-enable it in vehicle settings and verify proper integration with friction brakes

Related trouble codes on this vehicle

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