This procedure removes and replaces the front brake pads on a 2022 Rivian EDV 500 commercial electric delivery van, including caliper service and brake system verification.

Warnings

Tools required

Parts

• Front brake pad set (complete for both sides) × 1 — Use OEM Rivian specification
• Brake caliper hardware kit (clips and springs) × 1 — Use OEM Rivian specification
• Anti-seize compound (copper-free for aluminum) × 1 — Use copper-free formula
• Brake caliper lubricant (high-temp synthetic) × 1 — Use silicone or synthetic formula

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake firmly.
2. Verify high voltage system is disabled: Access vehicle settings and initiate service mode to disable high voltage battery contactor. Wait 5 minutes after disabling before beginning work.
3. Use digital multimeter to verify zero voltage at high voltage junction box (consult service manual for test point locations).
4. Chock rear wheels securely on both sides.
5. Remove brake fluid reservoir cap and extract approximately 2-3 oz of fluid with turkey baster to prevent overflow when compressing caliper pistons. Store in sealed container.
6. Loosen front wheel lug nuts one full turn while vehicle is on ground (do not remove).
7. Lift front of vehicle with floor jack at designated front jacking points (refer to owner's manual for exact locations on frame rails).
8. Place jack stands under designated support points and lower vehicle onto stands. Shake vehicle to verify stability.
9. Remove front wheels completely and set aside.

Procedure

1. 1

   Inspect brake system condition
   Thoroughly inspect both front brake assemblies before disassembly. Check rotor thickness and condition for scoring, cracking, or uneven wear. Measure rotor thickness with micrometer if available; minimum thickness should be stamped on rotor hat. Inspect brake hoses for cracks, bulges, or leaks. Check caliper mounting points for damage or corrosion. Take photos for reference. If rotors are below minimum thickness or show deep scoring, this procedure must include rotor replacement.
2. 2

   Remove caliper slide bolts
   Locate the two caliper slide bolts (guide pins) on the rear of the caliper assembly. These are typically 13mm or 15mm hex head bolts. Clean area around bolts with brake cleaner. Remove the lower caliper slide bolt completely. Remove the upper caliper slide bolt completely. Keep bolts organized and inspect threads for damage.
3. 3

   Remove brake caliper
   Carefully pivot the caliper up and away from the rotor. The caliper is still connected to the brake line - do NOT let it hang by the brake hose. Support the caliper weight using a caliper hanger hooked to the suspension or secure it with wire to the strut assembly. Ensure no tension or stress is placed on the brake line.
4. 4

   Remove old brake pads and hardware
   Remove the outboard brake pad from the caliper bracket (it may be held by spring clips). Remove the inboard brake pad from the caliper bracket. Remove all pad retaining clips, anti-rattle springs, and shims from the caliper bracket. Note the orientation and position of all hardware for reinstallation. Inspect caliper bracket for wear, cracks, or damage.
5. 5

   Clean caliper bracket and slides
   Thoroughly clean the caliper bracket with brake parts cleaner and wire brush, paying special attention to the pad slide channels where the brake pad ears sit. Remove all rust, debris, and old lubricant. Clean the caliper slide pins thoroughly and inspect the rubber boots for tears or damage. If boots are damaged, they must be replaced. Wipe down the caliper bracket mounting surface on the steering knuckle.
6. 6

   Compress caliper pistons
   Place the brake caliper piston compression tool or large C-clamp against the back of the caliper piston. Use an old brake pad as a backing plate to distribute pressure evenly. Slowly compress the piston(s) back into the caliper bore. Watch the brake fluid reservoir - fluid level will rise as pistons are compressed. If reservoir begins to overflow, remove more fluid. Continue compressing until piston is fully retracted and flush with caliper bore. For multi-piston calipers, compress all pistons evenly.
7. 7

   Lubricate caliper hardware
   Apply thin coat of high-temperature brake lubricant to the caliper slide pins (guide pins) - do NOT use anti-seize on slide pins. Apply thin layer of brake lubricant to the pad slide channels in the caliper bracket where the brake pad ears contact. Apply lubricant to the back of the new pad shims or anti-rattle clips. Do NOT get any lubricant on the pad friction material or rotor surface.
8. 8

   Install new brake pad hardware
   Install new pad retaining clips into the caliper bracket, ensuring they snap fully into place and match the orientation of the original hardware. Install new anti-rattle springs and shims according to the hardware kit instructions. Verify all hardware is secure and properly seated before proceeding.
9. 9

   Install new brake pads
   Install the new inboard brake pad into the caliper bracket, ensuring the pad ears fit properly into the slide channels and any wear indicators are positioned correctly (typically at the top of the pad). Install the new outboard brake pad into the caliper bracket, ensuring proper engagement with retaining clips. Verify both pads move smoothly in their channels and are properly seated against the hardware.
10. 10

    Reinstall brake caliper
    Remove the caliper from its hanger or wire support. Carefully position the caliper over the new brake pads and align the caliper slide pin holes with the bracket bushings. Clean the threads of both caliper slide bolts with brake cleaner. Apply a thin coat of anti-seize compound (copper-free) to the slide bolt threads. Insert and hand-thread both caliper slide bolts to prevent cross-threading.
11. 11

    Torque caliper slide bolts
    Tighten both caliper slide bolts following a proper torque sequence. Since torque specifications are not available in the database, you must obtain the correct torque value from Rivian service documentation before completing this step. Typical values for commercial vehicles range from 25-35 ft-lbs, but DO NOT GUESS. Over-torquing can damage components; under-torquing can cause caliper detachment and brake failure. Verify both bolts are torqued equally.
    ⚠️Improper torque on caliper bolts can result in brake failure. You must obtain correct torque specifications from Rivian before proceeding.
12. 12

    Repeat for opposite side
    Perform steps 2 through 11 on the opposite front brake assembly. Always replace brake pads on both sides of an axle simultaneously to maintain balanced braking performance. Ensure both sides are completed to the same standard with all hardware properly installed and lubricated.
13. 13

    Reinstall wheels
    Clean the wheel hub mating surface with wire brush to remove any rust or debris. Position wheel onto hub and hand-thread all lug nuts to prevent cross-threading. Tighten lug nuts in a star pattern (not circular) finger-tight only while vehicle is still on jack stands.
14. 14

    Lower vehicle and torque wheels
    Raise vehicle slightly with floor jack to remove weight from jack stands. Remove jack stands and carefully lower vehicle to ground. Torque wheel lug nuts in a star pattern to manufacturer specification (consult owner's manual - typically 120-150 ft-lbs for commercial vehicles of this weight, but verify specific value for EDV 500). Make three complete passes in star pattern to ensure even seating.
15. 15

    Restore brake system and bed pads
    Add DOT 4 brake fluid to reservoir if needed to bring level to MAX line. Reinstall reservoir cap. Pump brake pedal slowly and firmly 10-15 times until pedal feels firm and returns to normal height - this repositions the caliper pistons against the new pads. Check brake fluid level again and top off if needed. Re-enable high voltage system by exiting service mode. Perform initial test stops at low speed in a safe area. Perform proper pad bedding procedure: make 10-15 moderate stops from 30-40 mph with 3-5 second cooling intervals between stops to properly bed the new pads to the rotors.

Reassembly

1. Ensure both front brake assemblies have been serviced with new pads and hardware installed symmetrically.
2. Verify all caliper slide bolts are properly torqued (obtain specifications from Rivian service documentation).
3. Verify wheel lug nuts are torqued to specification in star pattern.
4. Confirm brake pedal is firm and returns to normal height after pumping.
5. Confirm brake fluid reservoir is filled to MAX line with DOT 4 fluid.
6. Verify high voltage system has been re-enabled and vehicle is operational.

Verification

• Pump brake pedal 15-20 times - pedal should feel firm and consistent, not spongy or going to floor.
• With engine/vehicle on, verify brake pedal height is normal and holds firm pressure without slowly sinking.
• Check brake fluid reservoir - level should be at MAX line with no visible leaks.
• Visually inspect both front calipers for proper installation and no fluid leaks around brake lines.
• Perform low-speed test stops (5-10 mph) in a safe area - braking should be smooth with no pulling to either side, no grinding noises, and vehicle should stop straight.
• After test drive, check wheel area for any unusual heat (some heat is normal, but one side significantly hotter indicates a dragging caliper).
• Re-check wheel lug nut torque after first 50-100 miles of driving.
• Monitor brake pedal feel and performance for the first several hundred miles during pad break-in period.
• If pedal feels soft, vehicle pulls during braking, or any unusual noises occur, stop driving immediately and have system inspected by qualified technician.

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