Brake Rotor - Rear Single

This procedure covers the removal and replacement of a single rear brake rotor on a 2022 Rivian EDV 500 electric delivery van, including safe vehicle support, caliper removal, and proper reassembly.

Warnings

Tools required

Parts

• Rear brake rotor × 1 — Use OEM Rivian specification or equivalent meeting Rivian standards
• Brake caliper bracket bolts (if corroded) × 2 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on a level, solid surface and engage parking brake (or chock front wheels if rear parking brake is affected)
2. Power down the vehicle completely and ensure it is in Park mode
3. Place wheel chocks in front of both front wheels for additional safety
4. Loosen rear wheel lug nuts while vehicle is on the ground (do not remove)
5. Locate proper jacking points per Rivian service manual - incorrect jacking can damage high-voltage battery pack
6. Raise rear of vehicle with floor jack at designated jacking point
7. Place jack stands at manufacturer-specified support points and lower vehicle onto stands
8. Remove rear wheel and set aside in safe location
9. Verify vehicle is stable before proceeding with any work underneath

Procedure

1. 1

   Inspect brake system and document condition
   Visually inspect the brake caliper, rotor, brake lines, and pad condition. Take photos or notes of brake pad thickness, rotor condition, and any fluid leaks. This documentation helps ensure you're addressing the correct issue and provides a baseline for post-repair verification.
2. 2

   Remove brake caliper mounting bolts
   Locate the two caliper slide bolts on the back of the caliper assembly. Using a socket wrench, remove both caliper slide bolts completely. On electric vehicles, these bolts may have thread-locking compound. If bolts are difficult to remove, apply penetrating lubricant and wait 10-15 minutes before attempting removal.
   ⚠Do not allow the caliper to hang by the brake hose - this can damage the hose and cause brake failure.
3. 3

   Support and secure brake caliper
   Carefully lift the brake caliper off the rotor and bracket. Use wire, bungee cord, or caliper hanger hooks to suspend the caliper from the suspension or chassis. Ensure there is no tension or strain on the rubber brake hose. The caliper should hang freely without pulling on the brake line.
4. 4

   Remove caliper bracket
   Locate the two caliper bracket bolts that secure the bracket to the hub assembly. These bolts are typically larger than the caliper slide bolts and may require significant force to remove. Use a breaker bar if necessary. Remove both bolts completely and remove the caliper bracket. Keep track of any shims or anti-rattle clips.
   ℹ️Caliper bracket bolts are high-torque fasteners. Mark orientation of bracket before removal for proper reinstallation.
5. 5

   Remove brake rotor
   Pull the brake rotor straight off the wheel hub. If the rotor is stuck due to corrosion, tap it gently from behind with a rubber mallet while rotating. If rotor has threaded holes, you can thread bolts into them to push the rotor off evenly. Do not hit the rotor on the friction surface or use excessive force that could damage the wheel bearing.
6. 6

   Clean hub surface
   Use a wire brush to thoroughly clean the wheel hub mounting surface, removing all rust, corrosion, and debris. Clean the hub face where the rotor seats to ensure even rotor mounting. Any debris or rust between the hub and rotor will cause rotor runout and brake pulsation. Clean the wheel studs and threads as well.
7. 7

   Install new brake rotor
   Remove any protective coating from the new rotor using brake cleaner and a clean cloth. Apply a thin layer of anti-seize compound to the hub face (not on rotor friction surfaces). Slide the new rotor onto the hub, ensuring it seats fully and evenly against the hub face. If rotor has directional cooling vanes, verify correct orientation per manufacturer markings.
   ⚠Never touch rotor friction surfaces with bare hands - oils from skin will cause brake noise and reduced performance. Use clean gloves or handle by edges only.
8. 8

   Reinstall caliper bracket
   Position the caliper bracket over the rotor and align with mounting holes on the hub assembly. Apply thread-locking compound to caliper bracket bolts if originally equipped. Install both bracket bolts and tighten using a torque wrench to manufacturer specification (specification not available in database - consult Rivian service manual). Reinstall any shims or anti-rattle clips in their original positions.
9. 9

   Inspect and clean brake pads
   Inspect brake pads for wear, cracking, or contamination. If pads show uneven wear or are below minimum thickness (typically 3mm), they should be replaced. Clean pad backing plates with wire brush. Apply disc brake quiet compound to pad backing plates if desired. Ensure pad hardware and anti-rattle clips are clean and properly positioned.
10. 10

    Compress caliper piston
    Before reinstalling the caliper, the piston must be compressed to accommodate the new rotor and pads. Use a brake caliper compression tool or large C-clamp to slowly push the piston back into the caliper bore. This will force brake fluid back into the reservoir. Check the master cylinder reservoir periodically to ensure it does not overflow.
    ⚠Monitor brake fluid reservoir during piston compression. If reservoir is full, fluid may overflow causing paint damage and creating a safety hazard.
11. 11

    Reinstall brake caliper
    Remove the caliper from its supported position and carefully position it over the new rotor and brake pads. Align the caliper with the slide bolt holes. Install both caliper slide bolts and tighten to manufacturer specification using a torque wrench (specification not available in database - consult Rivian service manual). Ensure caliper moves freely on slide pins.
12. 12

    Reinstall wheel and lower vehicle
    Clean wheel mounting surface on rotor hat. Mount the wheel onto the hub, aligning lug nut holes. Hand-tighten all lug nuts in a star pattern. Raise vehicle slightly with floor jack to remove load from jack stands, then remove jack stands. Lower vehicle completely to ground. Torque lug nuts to specification in star pattern (specification not available in database - typically 120-150 ft-lb for this class of vehicle, but verify with Rivian manual).

Reassembly

1. Double-check all fasteners are properly torqued using a torque wrench - do not rely on feel or impact tools for final tightening
2. Verify brake caliper moves freely and is not binding on the rotor
3. Ensure no tools or parts were left in the wheel well area
4. Check brake fluid level in master cylinder reservoir and top off with DOT 4 brake fluid if needed - do not overfill

Verification

• Before moving vehicle, pump brake pedal slowly 10-15 times until firm resistance is felt - this repositions the caliper piston against the new rotor
• Check brake pedal feel - pedal should be firm and not sink to floor. If pedal is soft or sinks, there may be air in the system requiring bleeding
• Perform a slow-speed brake test in a safe area to verify proper brake function before returning to normal driving
• Listen for any unusual noises during initial brake applications - slight noise during first few applications is normal as pads seat to new rotor
• Verify no brake fluid leaks around caliper, brake lines, or master cylinder
• Test drive at various speeds in a safe area, verifying straight-line braking with no pulling to either side
• Perform 15-20 moderate brake applications from 30-40 mph to properly bed-in the new rotor and pads per brake manufacturer recommendations
• Avoid heavy braking for first 200-300 miles to allow proper pad and rotor break-in

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