Brake Rotors - Rear Pair

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

Warnings

Tools required

Parts

• Rear brake rotor × 2 — Use OEM specification for EDV 500
• Brake hardware kit (if applicable) × 1 — Use OEM specification
• Brake caliper bracket bolts (if corroded) × 4 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on a flat, level surface with adequate space to work on both sides
2. Verify the vehicle is in Park mode and apply the parking brake (front wheels only on this AWD vehicle)
3. Chock the front wheels securely
4. Place wheel chocks or blocks in front of and behind the front wheels
5. If available, remove a small amount of brake fluid from the master cylinder reservoir using a turkey baster to prevent overflow when compressing caliper pistons
6. Loosen rear wheel lug nuts 1/4 turn while wheels are on the ground
7. Lift the rear of the vehicle using the designated jacking points per owner's manual
8. Support the vehicle on jack stands at the reinforced frame support points - never under suspension components or battery pack
9. Remove the rear wheels completely and set aside

Procedure

1. 1

   Inspect current brake system condition
   Before disassembly, inspect the brake caliper, brake lines, and surrounding components for leaks, damage, or excessive corrosion. Check that the parking brake cable (if integrated with rear calipers) moves freely. Measure the existing rotor thickness with a micrometer at multiple points to confirm replacement is necessary. Document any additional components that may need service.
2. 2

   Remove caliper mounting bolts
   Locate the two caliper bracket mounting bolts on the rear of the caliper assembly. These are typically 18mm bolts that secure the entire caliper bracket to the steering knuckle or axle housing. Apply penetrating oil if bolts show corrosion. Remove both caliper bracket bolts completely. Note: On some configurations, you may remove only the caliper slide pins to pivot the caliper upward, but full bracket removal provides better rotor access.
3. 3

   Remove caliper and bracket assembly
   Carefully lift the caliper and bracket assembly off the rotor. Do NOT let the caliper hang by the brake hose - this can damage the hose internally. Use a brake caliper hanger, wire, or bungee cord to suspend the caliper from the suspension or frame. Ensure no tension is placed on the brake line. Keep the caliper upright if possible to prevent air from entering the system.
4. 4

   Remove old rotor
   The rotor should slide off the wheel hub once the caliper is removed. If the rotor is stuck due to rust or corrosion on the hub surface, use a rubber mallet to tap around the hat section of the rotor (the center portion). Do not strike the friction surface. If severely stuck, thread bolts into the threaded holes on the rotor face (if equipped) to press the rotor off the hub. Remove the rotor completely.
5. 5

   Clean hub mounting surface
   Use a wire brush to thoroughly clean the wheel hub mounting surface, removing all rust, scale, and debris. The hub face must be completely flat and clean to prevent rotor runout and vibration. Clean the wheel pilot bore and hub centering ring. If significant rust or pitting is present, consider having the hub resurfaced or replaced. Apply a thin coat of anti-seize compound to the hub face (avoid getting any on the wheel studs).
6. 6

   Prepare new rotor
   Remove new rotors from packaging. New rotors have a protective oil coating to prevent rust during shipping - this MUST be removed. Spray both sides of each rotor thoroughly with brake parts cleaner and wipe with a clean, lint-free cloth. Repeat until no oily residue remains. Do not touch the friction surfaces with bare hands after cleaning.
7. 7

   Install new rotor
   Slide the new rotor onto the wheel hub, ensuring it seats fully and flat against the cleaned hub surface. If the rotor has a directional arrow or marking (left/right), ensure correct installation. Temporarily install two wheel lug nuts (with washers if available) to hold the rotor in place during caliper installation. This prevents the rotor from shifting during the next steps.
8. 8

   Compress caliper pistons
   Before reinstalling the caliper, the piston(s) must be compressed to accommodate the thicker new rotor and unworn brake pads. Place the caliper on a clean work surface. Use a C-clamp or brake caliper piston compression tool to slowly press the piston(s) back into the caliper bore. Watch the brake fluid reservoir - it will rise as the piston is compressed. If it approaches the MAX line, remove some fluid. Compress the piston until it is fully retracted and flush with the caliper housing.
9. 9

   Inspect and prepare caliper bracket
   Clean the caliper bracket thoroughly with a wire brush and brake cleaner. Inspect the brake pad slide points and hardware. If the brake hardware kit (clips, shims, anti-rattle springs) shows wear, replace with new components from the hardware kit. Apply a thin film of high-temperature brake lubricant to the pad slide areas only - never on the friction surfaces. Ensure caliper slide pins move freely if equipped.
10. 10

    Reinstall caliper and bracket assembly
    Remove the temporary lug nuts from the rotor. Position the caliper bracket over the new rotor, aligning the mounting holes with the threads in the steering knuckle or axle housing. Insert the caliper bracket bolts and hand-thread them completely. Note: Manufacturer torque specifications are not available in this database. Rivian EDV caliper bracket bolts typically require significant torque (80-120 ft-lbs range is common for commercial vehicles). CRITICAL: Contact a Rivian service center or consult the official service manual for exact torque specifications before tightening. Improper torque can cause caliper detachment and complete brake failure.
11. 11

    Reinstall wheel and lower vehicle (first side)
    Install the wheel onto the hub, ensuring it seats properly on the hub pilot. Thread all wheel lug nuts by hand. Tighten the lug nuts in a star pattern to snug fit with a hand wrench. Do not fully torque while vehicle is on jack stands. Repeat all steps (1-11) for the second rear rotor. Once both rear rotors are replaced and wheels are hand-tight, lower the vehicle until the wheels just contact the ground but the suspension is not fully loaded.
12. 12

    Torque wheel lug nuts
    With the vehicle weight partially on the wheels, torque all rear wheel lug nuts to manufacturer specification using a torque wrench in a star/cross pattern. For the Rivian EDV 500, wheel lug nut torque is typically in the 160-180 ft-lbs range for commercial vehicles, but verify the exact specification on the door jamb sticker or owner's manual. Fully lower the vehicle and remove jack stands. Perform final torque verification of all lug nuts in star pattern.
13. 13

    Verify brake fluid level
    Open the hood and locate the brake fluid reservoir. Check that the fluid level is between the MIN and MAX marks. Add DOT 4 brake fluid if necessary to bring to the proper level. Do not overfill. Ensure the reservoir cap is secured tightly.
14. 14

    Pump brake pedal and test
    Before moving the vehicle, sit in the driver's seat and pump the brake pedal slowly 10-15 times until it becomes firm and reaches normal height. The pedal should feel solid - if it remains soft or goes to the floor, there is air in the system or a leak. Do NOT drive the vehicle if the pedal is soft. With the vehicle still stationary and in Park, apply firm brake pressure and verify it holds steady. Check under the vehicle for any brake fluid leaks around the calipers.
15. 15

    Perform bedding-in procedure
    New rotors and pads must be properly bedded to achieve full braking performance and prevent vibration. Find a safe, empty stretch of road or parking area. Perform 8-10 moderate stops from 40-45 mph down to 15 mph with moderate pedal pressure, allowing 30 seconds of light driving between stops to cool. Do NOT come to a complete stop while brakes are hot as this can transfer pad material unevenly. Then perform 2-3 firmer stops from 50-55 mph down to 20 mph with heavier pedal pressure. Allow brakes to cool for 5-10 minutes of gentle driving without using brakes. Expect some brake odor and light smoke during bedding - this is normal. Avoid heavy braking for the first 200-300 miles.

Reassembly

1. Reassembly is covered in the main procedure steps
2. Ensure all caliper bracket bolts are torqued to manufacturer specification (consult Rivian service documentation)
3. Verify wheel lug nuts are torqued to specification in star pattern
4. Confirm brake fluid level is correct and reservoir cap is tight
5. Double-check that no tools or parts were left near the brake components or wheels

Verification

• Start the vehicle and verify the brake warning light is not illuminated on the dashboard
• Pump the brake pedal - it should be firm and hold steady pressure within 3-4 pumps
• Visually inspect all four corners for brake fluid leaks with the vehicle running
• Perform a low-speed test drive in a safe area, testing brake response at 5-10 mph before proceeding
• During the bedding-in procedure, monitor for any vibration, pulsation, or unusual noises that could indicate improper installation
• After bedding-in is complete and brakes are cool, verify the pedal feel remains firm and braking is smooth and even
• Recheck wheel lug nut torque after 50-100 miles of driving
• If any vibration, soft pedal, pulling to one side, or unusual noises occur, stop driving immediately and have the system inspected by a qualified technician

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