Complete rebuild of front brake calipers on a 2022 Rivian EDV 500, including disassembly, cleaning, seal replacement, and reassembly with proper bleeding procedures.

Warnings

Tools required

Parts

• Front brake caliper rebuild kit (includes seals, dust boots, and hardware) × 2 — Use OEM Rivian specification
• Brake caliper guide pin boots × 2 — Use OEM specification
• Brake caliper guide pin grease × 1 — High-temperature synthetic brake grease
• Brake assembly lubricant × 1 — Silicone-based brake lubricant
• Copper crush washers for brake lines × 4 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Open hood and disconnect 12V battery negative terminal. Wait 5 minutes for system capacitors to discharge
4. Ensure vehicle is in Park mode and key fob is removed from vehicle
5. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
6. Raise front of vehicle using floor jack at designated lift points on frame rails
7. Secure vehicle on jack stands rated for at least 8000 lbs at proper support points
8. Remove front wheels completely and set aside
9. Clean brake caliper area with brake cleaner to remove road debris and contamination
10. Open brake fluid reservoir and check fluid level. Do NOT overfill
11. Place absorbent material under brake calipers to catch fluid spillage
12. Have all rebuild kit components unpacked and inspected before disassembly

Procedure

1. 1

   Remove brake caliper from rotor
   Disconnect brake pad wear sensor connector if equipped by pressing release tab. Remove caliper mounting bolts (typically 17mm or 18mm). Carefully lift caliper off rotor without letting it hang by brake hose. Support caliper with wire or bungee cord to avoid stressing brake line.
2. 2

   Disconnect brake hose from caliper
   Place drain pan under connection point. Using two wrenches to prevent twisting, disconnect brake hose from caliper (typically 11mm line nut). Immediately cap or plug brake line and caliper port to prevent fluid loss and contamination. Remove copper crush washers and discard. Remove caliper to workbench area.
3. 3

   Remove brake pads and hardware
   Remove brake pads from caliper bracket if still installed. Remove anti-rattle clips, shims, and any guide pin hardware. Inspect caliper bracket for wear or damage. Clean bracket thoroughly with brake cleaner. Set all hardware aside for cleaning or replacement per rebuild kit instructions.
4. 4

   Remove caliper pistons
   Place caliper on workbench with piston facing up, positioned over a container with rags. Using low-pressure compressed air (30 PSI or less) applied to brake fluid inlet port, carefully blow pistons out of caliper bore. Control piston ejection with rags - pistons will come out with force. NEVER place fingers in front of piston during this operation. If pistons are seized, soak with penetrating oil for 30 minutes and retry.
   ⚠️Pistons can eject with extreme force causing crush injuries. Keep hands clear of piston path and use protective equipment.
5. 5

   Remove piston seals and dust boots
   Using plastic or brass pick tools (NEVER metal tools), carefully remove dust boots from caliper bore grooves. Remove piston seal from inner groove in caliper bore - be extremely careful not to scratch or gouge the bore surface. Any scratches in the bore will cause leaks and caliper failure. Remove all old seal material completely.
6. 6

   Clean and inspect caliper components
   Clean all metal caliper components thoroughly using brake parts cleaner or isopropyl alcohol. Inspect caliper bore for scoring, pitting, corrosion, or scratches. Bore must be smooth and mirror-like - any defects require caliper replacement. Inspect pistons for scoring, corrosion, or chrome plating damage. Clean pistons thoroughly. Inspect caliper body for cracks or damage. Dry all components with compressed air and lint-free rags.
   ⚠Any damage to caliper bore or piston sealing surfaces requires complete caliper replacement. Rebuilt damaged calipers will fail and cause brake system failure.
7. 7

   Lubricate and install new piston seals
   From rebuild kit, identify correct piston seals. Coat seals lightly with clean DOT 4 brake fluid (NEVER use petroleum-based lubricants). Carefully install seal into inner groove of caliper bore using fingers only - ensure seal seats completely and evenly in groove without twisting. Verify seal is properly seated by visual inspection around entire circumference.
8. 8

   Install dust boots and pistons
   Coat piston sealing surface lightly with clean DOT 4 brake fluid. Install new dust boot onto piston per rebuild kit instructions (some boots install on piston first, others install in caliper first - follow kit directions). Carefully guide piston straight into caliper bore, ensuring seal does not roll or twist. Use brake caliper piston tool or C-clamp to press piston fully into bore - piston must bottom out completely. Ensure dust boot seats properly in caliper groove. Repeat for second piston if dual-piston caliper.
9. 9

   Service caliper guide pins
   Remove guide pins from caliper bracket by pulling from boots. Clean guide pins thoroughly with brake cleaner and inspect for corrosion or damage. Replace if worn or corroded. Remove old guide pin boots and discard. Install new guide pin boots from rebuild kit into caliper bracket. Apply thin coat of high-temperature brake grease to guide pins (provided in kit or use synthetic caliper grease). Insert guide pins into boots - pins should slide freely.
10. 10

    Reconnect brake hose to caliper
    Install NEW copper crush washers on both sides of brake hose banjo bolt fitting. Position brake hose to caliper with proper orientation (hose should route naturally without twisting). Thread banjo bolt by hand to start, then tighten to manufacturer specification (typically 30-35 ft-lbs, but verify in service manual). Use two wrenches to prevent hose twisting. Ensure hose has proper clearance and will not contact suspension or wheel components through full steering travel.
11. 11

    Reinstall caliper assembly
    Apply thin coat of brake assembly lubricant to caliper bracket contact points where pads slide. Install anti-rattle clips and hardware per original configuration. Position caliper over rotor and align guide pins with caliper bracket holes. Thread caliper mounting bolts by hand, then tighten to manufacturer specification (typically 70-90 ft-lbs for front calipers - verify in service manual). Reconnect brake pad wear sensor connector if equipped. Verify caliper has proper clearance around rotor.
12. 12

    Bleed brake system
    Fill brake fluid reservoir to MAX line with fresh DOT 4 brake fluid. Starting with wheel farthest from master cylinder (typically right rear), attach bleeder hose and container to bleeder screw. Open bleeder screw 1/4 turn. Have assistant slowly depress brake pedal to floor, close bleeder screw before pedal returns, then release pedal. Repeat until fluid runs clear without bubbles. Tighten bleeder screw to specification (typically 7-10 ft-lbs). Repeat process for all four wheels in proper sequence (RR, LR, RF, LF). Check reservoir level frequently and never let it run dry.
    ⚠️If brake reservoir runs empty during bleeding, air will enter ABS system requiring specialized scan tool to bleed. Monitor reservoir constantly.
13. 13

    Perform system verification
    With engine off, pump brake pedal 15-20 times to verify pedal firmness. Pedal should become progressively firmer and hold pressure. Start vehicle and verify brake pedal remains firm with power assist active. Check all caliper connections and bleeder screws for leaks. Inspect brake fluid level and top off to MAX if needed. Test regenerative braking integration by gently applying brakes at low speed - transition should be smooth.

Reassembly

1. Repeat entire caliper rebuild procedure for opposite side front caliper
2. Reinstall front wheels and hand-tighten lug nuts in star pattern
3. Lower vehicle from jack stands to ground
4. Torque wheel lug nuts to manufacturer specification (typically 150 ft-lbs) in star pattern
5. Reconnect 12V battery negative terminal
6. Top off brake fluid reservoir to MAX line with DOT 4 brake fluid only
7. Close brake fluid reservoir cap securely
8. Clean any spilled brake fluid from components and painted surfaces immediately

Verification

• With vehicle running, pump brakes several times and verify firm pedal with no sponginess or excessive travel
• Perform static brake test: Press brake pedal firmly and hold for 60 seconds - pedal should not sink or feel soft
• Check all caliper bolts, brake line connections, and bleeder screws for any signs of brake fluid leakage
• Test drive in safe area at low speeds (under 15 mph) to verify proper brake function and pedal feel before normal operation
• Perform 3-4 moderate stops from 30 mph to bed-in new seals and verify even braking with no pulling
• Recheck brake fluid level after test drive and top off if needed
• Verify brake pad wear sensor connectors are properly connected and no warning lights are illuminated
• After 50-100 miles, recheck all caliper bolts for proper torque and inspect for any fluid leaks
• CRITICAL: Brakes may require break-in period. Avoid hard braking for first 200 miles. If pedal feel is not firm or braking performance seems reduced, DO NOT drive vehicle - seek professional service immediately

More procedures for this vehicle