Brake Rotors - Front Pair

This procedure covers the removal and replacement of both front brake rotors on a 2022 Rivian EDV 500 electric delivery van, including caliper removal and proper brake system handling.

Warnings

Tools required

Parts

• Front brake rotor × 2 — Use OEM specification - Rivian part recommended
• Brake hardware kit (if needed) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, stable ground and ensure it is powered off completely
2. Place wheel chocks behind rear wheels
3. Verify you have obtained proper torque specifications from Rivian service documentation for caliper bracket bolts, caliper mounting bolts, and wheel lug nuts before beginning
4. Loosen front wheel lug nuts while vehicle is still on ground (do not remove)
5. Safely raise front of vehicle using floor jack at designated lift points
6. Secure vehicle on jack stands rated for the vehicle weight at proper support points
7. Remove front wheels completely
8. Verify brake system is not excessively hot from recent driving; allow to cool if necessary
9. Check brake fluid level in reservoir and note current level for reference

Procedure

1. 1

   Access and inspect brake assembly
   With wheel removed, visually inspect the brake caliper, rotor, and brake lines for any damage, excessive wear, or fluid leaks. Identify caliper mounting bolts and caliper bracket bolts. Note the condition of brake pads for potential replacement during this service.
2. 2

   Prepare brake caliper for removal
   Use a C-clamp or brake caliper piston tool to slowly compress the caliper piston back into the caliper bore. Place the clamp between the back of the caliper and the outboard brake pad surface. This step is necessary to create clearance for caliper removal and prevent brake fluid overflow from the reservoir. Monitor the brake fluid reservoir to ensure it does not overflow; remove fluid with a turkey baster if needed.
3. 3

   Remove brake caliper mounting bolts
   Locate the caliper slide pin bolts or mounting bolts on the rear of the caliper assembly. These typically require a hex socket or Torx bit. Remove both mounting bolts completely while supporting the caliper with your other hand. Keep track of any washers or hardware.
4. 4

   Secure brake caliper
   Carefully lift the caliper off the rotor and brake pads. Do NOT let the caliper hang by the brake hose. Immediately support the caliper by hanging it from the suspension or chassis using heavy wire, zip ties, or a bungee cord. Ensure there is no tension or strain on the flexible brake hose. If pads are being reused, remove them and keep them in order.
5. 5

   Remove caliper bracket
   Locate the caliper bracket bolts (typically two larger bolts that secure the bracket to the steering knuckle or hub assembly). These bolts usually require significant force to remove. Use a breaker bar if necessary. Remove both bracket bolts completely and remove the caliper bracket assembly. Inspect bracket hardware for wear.
6. 6

   Remove old brake rotor
   With the caliper bracket removed, the rotor should slide off the wheel hub. If the rotor is stuck due to corrosion, gently tap it from behind with a dead blow hammer or rubber mallet. Do NOT strike the rotor friction surface. If the rotor has threaded holes, you can use bolts to press it off evenly. Remove the rotor completely.
7. 7

   Prepare hub surface
   Clean the wheel hub mounting surface thoroughly with a wire brush or sandpaper to remove rust, corrosion, and debris. The hub surface must be clean and flat to ensure the new rotor seats properly and runs true without wobble. Use brake cleaner to remove any residue or oil.
8. 8

   Install new brake rotor
   Remove any protective coating from the new rotor using brake cleaner and allow to dry. Place the new rotor onto the wheel hub, ensuring it seats fully and flush against the hub surface. If the rotor has directional cooling vanes, verify correct orientation (typically indicated by arrows on the rotor). Temporarily install one lug nut to hold the rotor in place during reassembly if needed.
9. 9

   Reinstall caliper bracket
   Position the caliper bracket back onto the steering knuckle or hub assembly. Apply a small amount of medium-strength thread locker to the bracket bolt threads. Install both caliper bracket bolts and hand-tighten. Torque bracket bolts to manufacturer specification using a torque wrench. Without manufacturer specifications, DO NOT proceed until proper torque values are obtained.
10. 10

    Install brake pads and caliper
    If installing new brake pads, apply brake lubricant to pad hardware contact points (NOT to friction surfaces). Install brake pads into the caliper bracket. Remove the caliper from its supported position and carefully position it over the brake pads and rotor. Align the caliper mounting holes with the slide pins or bracket.
11. 11

    Install caliper mounting bolts
    Install both caliper mounting bolts with any washers or hardware. Apply thread locker if specified by manufacturer. Hand-tighten both bolts, then torque to manufacturer specification using a torque wrench. Verify the caliper moves freely on its slide pins if equipped.
12. 12

    Repeat procedure on opposite side
    Complete the identical procedure for the opposite front brake rotor following steps 1 through 11. Both front rotors must be replaced together to ensure even braking performance and prevent brake pull.
13. 13

    Reinstall wheels and lower vehicle
    Reinstall both front wheels. Hand-tighten all lug nuts in a star pattern. Lower the vehicle until tires just touch the ground but vehicle weight is not fully on wheels. Torque lug nuts to manufacturer specification in a star pattern. Completely lower vehicle and remove jack stands.
14. 14

    Restore brake pedal pressure
    Before moving the vehicle, pump the brake pedal slowly several times until firm resistance is felt. This repositions the caliper pistons against the new rotors. The pedal should feel firm and normal. If the pedal feels soft or goes to the floor, DO NOT drive the vehicle - there is a problem that must be corrected.
15. 15

    Check brake fluid and test system
    Check the brake fluid reservoir and top off with DOT 4 brake fluid if necessary to bring level to the MAX line. Verify there are no fluid leaks at any brake connections. Test brake function at low speed in a safe area before returning to normal driving.

Reassembly

1. Ensure all caliper and bracket bolts are torqued to manufacturer specifications
2. Verify brake calipers move freely and are not binding
3. Confirm brake fluid level is correct and reservoir cap is secured
4. Double-check that all tools and parts have been removed from wheel wells
5. Verify wheels are torqued properly in star pattern

Verification

• Pump brake pedal multiple times - pedal should be firm before reaching halfway to floor
• Inspect under vehicle for any brake fluid leaks at calipers and connections
• Perform low-speed brake test in safe area to verify proper brake function and no unusual noises
• Test drive at varying speeds to bed-in new rotors and verify no vibration, pulling, or unusual sounds
• After first 50-100 miles, recheck wheel lug nut torque
• Follow manufacturer recommendations for new rotor bedding procedure if provided
• If ANY abnormality is detected (soft pedal, pulling, noise, vibration), stop driving immediately and have vehicle professionally inspected

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