This procedure covers the removal and replacement of the brake caliper bracket on a 2023 Rivian EDV 500 commercial van, which secures the brake caliper to the knuckle assembly.

Warnings

Tools required

Parts

• Brake caliper bracket × 1 — Use OEM Rivian specification
• Caliper bracket mounting bolts × 2 — Use OEM specification - replace if corroded
• Brake pads (if worn or contaminated) × 1 — Use OEM Rivian specification
• Brake pad hardware clips × 1 — Replace with bracket

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on a level, paved surface and engage parking brake
2. Place wheel chocks behind the wheels that will remain on the ground
3. Verify that the high-voltage system is de-energized: check the instrument cluster for any high-voltage warnings
4. Using a multimeter, verify that the 12V battery shows normal voltage (approximately 12.6V) to ensure vehicle electrical systems are functioning
5. Loosen wheel lug nuts while vehicle is on the ground (do not remove)
6. Raise vehicle using floor jack at designated lift points specified in owner's manual for this commercial vehicle
7. Support vehicle on manufacturer-approved jack stands - verify stability before working underneath
8. Remove wheel completely and set aside
9. Spray caliper bracket bolts with penetrating oil if corrosion is present and allow to soak for 10-15 minutes
10. Prepare a clean workspace for removed components

Procedure

1. 1

   Remove brake caliper from bracket
   Locate the two caliper slide pin bolts or caliper mounting bolts on the back side of the caliper. These are typically 14mm or 17mm hex bolts. Remove both bolts completely. Carefully lift the caliper off the bracket and brake pads. Immediately secure the caliper to the suspension or frame using wire, bungee cord, or a caliper hanger. Ensure there is no tension or weight on the brake hose. Do not disconnect the brake hose unless replacing the caliper.
   ⚠️Never let the caliper hang by the brake hose. Secure it immediately after removal.
2. 2

   Remove brake pads and hardware
   Remove the brake pads from the caliper bracket. Note the orientation and position of any anti-rattle clips, shims, or hardware for proper reinstallation. Remove all pad hardware clips from the bracket - these should be replaced with the new bracket. Take photos if needed to document the original configuration.
   ⚠Inspect brake pads for uneven wear which may indicate caliper or bracket issues. Replace pads if thickness is below 3mm or if contaminated with brake fluid or grease.
3. 3

   Inspect brake rotor and surrounding components
   With the bracket still installed, visually inspect the brake rotor for deep scoring, cracks, or heat discoloration. Check the rotor thickness if a micrometer is available. Inspect the wheel hub area for damage. Look for any signs of brake fluid leakage around the caliper or hose connections. Check the brake hose for cracks, abrasion, or bulging.
   ℹ️Electric vehicles often have reduced brake wear due to regenerative braking, but this can also cause surface rust on rotors. Light surface rust is normal if wiped off during braking.
4. 4

   Remove caliper bracket mounting bolts
   Locate the two large caliper bracket mounting bolts that secure the bracket to the steering knuckle or axle housing. These are typically 18mm-21mm bolts and will be very tight. Using a breaker bar or impact gun, remove both bracket mounting bolts. The bolts may have thread locker compound. If bolts are extremely tight, apply additional penetrating oil and allow to soak. Apply steady, even pressure to avoid rounding the bolt heads.
   ⚠These bolts are torqued to very high specifications (typically 120-180 ft-lb). Use appropriate tools to avoid stripping or rounding the bolt heads.
5. 5

   Remove caliper bracket
   Once both mounting bolts are removed, pull the caliper bracket away from the knuckle. If the bracket is stuck due to corrosion, gently tap with a rubber mallet or carefully use a pry bar. Do not damage the knuckle surface or mounting threads. Set the old bracket aside.
6. 6

   Clean mounting surfaces
   Thoroughly clean the mounting surface on the steering knuckle or axle housing where the bracket attaches. Use a wire brush to remove all rust, corrosion, brake dust, and old thread locker compound. Clean the bolt holes in the knuckle carefully. Spray with brake cleaner and wipe dry. The mounting surface must be completely clean and flat for proper bracket seating.
   ⚠Any debris or corrosion on mounting surfaces can prevent proper bracket alignment and torque retention.
7. 7

   Inspect and prepare new caliper bracket
   Unpack the new caliper bracket and verify it matches the original. Check that all mounting holes and pad contact surfaces are clean. Install new pad hardware clips into the bracket according to manufacturer instructions or your reference photos. Ensure clips are fully seated and secure.
8. 8

   Prepare bracket mounting bolts
   Inspect the bracket mounting bolts. If they show any signs of damage, stretching, or excessive corrosion, replace them with new OEM bolts. Clean the bolt threads with a wire brush. Apply medium-strength thread locker to the bolt threads according to the thread locker manufacturer's instructions (typically 2-3 threads from the tip).
   ℹ️Some manufacturers specify thread locker while others do not. Consult the service manual for this specific vehicle.
9. 9

   Install new caliper bracket
   Position the new caliper bracket onto the knuckle, aligning the mounting bolt holes. Start both bracket mounting bolts by hand to ensure proper thread engagement. Thread each bolt in several turns by hand before using any tools. Once both bolts are hand-tight and the bracket is properly seated, you are ready to torque.
   ⚠️Cross-threading these critical bolts can destroy the knuckle threads and require expensive knuckle replacement. Always start bolts by hand.
10. 10

    Torque caliper bracket mounting bolts
    Using a calibrated torque wrench and the manufacturer-specified torque value from the Rivian service manual, torque both bracket mounting bolts in a criss-cross pattern. Typical specifications for commercial vehicles range from 120-180 ft-lb, but you MUST use the exact specification for this vehicle. After reaching the specified torque, mark the bolt heads and bracket with a paint pen to provide visual verification of proper torque.
    ⚠️CRITICAL: You must obtain and use the exact torque specification from Rivian service documentation. Incorrect torque can result in bracket failure and total brake system failure.
11. 11

    Install brake pads
    Install the brake pads into the new bracket, ensuring they seat properly in the hardware clips. Verify that pads move freely in the bracket without binding. If installing new pads, remove any protective coating or backing according to manufacturer instructions. Ensure the wear indicator (if equipped) is positioned correctly.
12. 12

    Reinstall brake caliper
    Before reinstalling the caliper, check that the caliper pistons are fully retracted. If needed, use a brake caliper compression tool to carefully compress the pistons. Remove the caliper from its support wire/hanger and carefully position it over the brake pads and bracket. Install the caliper mounting bolts and torque according to manufacturer specifications (typically 30-45 ft-lb, but verify in service manual).
    ⚠Compressing the caliper pistons will push brake fluid back into the reservoir. Check the reservoir level and remove fluid if necessary to prevent overflow.
13. 13

    Reinstall wheel and lower vehicle
    Clean the wheel hub surface and wheel mounting surface. Install the wheel onto the hub, starting all lug nuts by hand. Tighten lug nuts in a star pattern until snug but not fully torqued. Carefully raise the vehicle slightly to remove jack stands. Lower the vehicle to the ground. With vehicle weight on the wheel, torque lug nuts to manufacturer specification in a star pattern (typically 140-160 ft-lb for this commercial vehicle, but verify in manual).

Reassembly

1. Before driving, pump the brake pedal slowly until firm pedal pressure is achieved - this reseats the caliper pistons against the new pads
2. Check brake fluid level in the master cylinder reservoir and top off with DOT 4 brake fluid if needed - do not overfill
3. Verify that the brake pedal feels firm and does not sink to the floor
4. Inspect all work areas to ensure no tools or parts were left under the vehicle
5. If multiple wheels were serviced, verify torque on all wheel lug nuts

Verification

• Start the vehicle and verify no brake warning lights are illuminated on the instrument cluster
• With the vehicle still stationary, firmly press the brake pedal multiple times - it should feel firm and consistent with no excessive travel
• Perform a low-speed test drive in a safe area (empty parking lot) at 5-10 mph and apply brakes gently to verify proper operation
• Check for any unusual noises, vibrations, or pulling to one side during braking
• Perform a moderate brake application from 25 mph in a safe area to verify adequate stopping power
• After the test drive, carefully feel the wheel area near the brake - it should be warm but not excessively hot
• Re-inspect all bolts visually and verify paint marks are aligned, indicating no bolt rotation
• Check brake fluid level one final time after test drive
• If any abnormalities are detected (noise, vibration, pulling, soft pedal, warning lights), do not drive the vehicle and seek professional assistance immediately
• Have the brake system professionally inspected if you have any doubts about the repair quality
• Bedding-in new brake pads: Perform 10-15 moderate brake applications from 40 mph to 10 mph with 30 seconds between applications to properly bed the pads to the rotors - avoid hard braking for the first 200 miles

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