Brake Pads - Front

Replace front brake pads on a 2023 Rivian EDV 500, including caliper service and proper bedding procedure for this electric commercial delivery vehicle.

Warnings

Tools required

Parts

• Front brake pad set (4 pads total) × 1 — Use OEM Rivian specification
• Brake pad anti-rattle clips (if applicable) × 1 — Verify with vehicle configuration
• Brake hardware kit (if needed) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground. Place wheel chocks behind rear wheels.
2. Turn vehicle OFF completely and ensure it is in PARK mode. Remove key fob from vehicle interior to prevent accidental activation.
3. Open driver's door and access the 12V battery disconnect or service mode via the vehicle's touchscreen settings (consult owner's manual for service mode activation).
4. Check brake fluid level in master cylinder reservoir. If near MAX line, remove approximately 2 oz with turkey baster to prevent overflow when compressing pistons. Store removed fluid in clean container.
5. Loosen front wheel lug nuts 1/4 turn while vehicle is still on ground.
6. Lift front of vehicle using floor jack at designated front jacking point and secure on jack stands at manufacturer-specified support points.
7. Remove both front wheels completely and set aside.

Procedure

1. 1

   Inspect brake system condition
   Before beginning disassembly, inspect brake rotors for scoring, cracking, or excessive wear. Measure rotor thickness with micrometer if available (minimum thickness stamped on rotor). Check brake hoses for cracks, bulging, or leaks. Check caliper slide pins for seized condition by attempting to push caliper inward slightly. Document any issues requiring additional service.
2. 2

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper (facing the vehicle interior). Using appropriate socket (typically 18mm), remove the upper and lower caliper slide pin bolts. Support the caliper with one hand while removing the second bolt to prevent it from falling. Note: These bolts thread into the caliper bracket and secure the floating caliper body.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Remove caliper from bracket
   Carefully pivot the caliper upward and away from the rotor. Support the caliper weight and secure it to the suspension or frame using a bungee cord or wire hanger. Never let the caliper hang by the brake hose as this can cause internal hose damage and brake failure. Inspect the brake hose connection to caliper for any signs of leakage.
4. 4

   Remove old brake pads and hardware
   Remove the inboard and outboard brake pads from the caliper bracket. Note the orientation and position of any anti-rattle clips, shims, or springs for reinstallation. Remove and inspect all pad hardware clips from the caliper bracket. If clips are bent, rusted, or damaged, replace with new hardware kit. Photograph pad position if helpful for reference during reassembly.
5. 5

   Clean caliper bracket and hardware
   Using wire brush and brake parts cleaner, thoroughly clean the caliper bracket, paying special attention to the pad slide channels where pads contact the bracket. Remove all rust, debris, and old grease buildup. Clean the caliper slide pin bores in the bracket. Inspect bracket for cracks or damage. A clean bracket ensures proper pad movement and even wear.
6. 6

   Inspect and lubricate caliper slide pins
   Remove both caliper slide pins from the bracket (they should slide out easily). Inspect pins for corrosion, scoring, or damage. Inspect the rubber slide pin boots for tears or deterioration - replace if damaged. Clean pins thoroughly with brake cleaner and wipe dry. Apply a thin, even coat of silicone brake grease to the smooth sliding portion of each pin (not the threaded portion). Reinstall pins into bracket, ensuring boots are properly seated.
   ⚠Only use silicone-based brake grease on slide pins. Petroleum-based grease will destroy rubber components and cause brake failure.
7. 7

   Compress caliper piston
   Using a brake caliper piston compression tool or large C-clamp, slowly compress the caliper piston fully into its bore. Position the tool against the piston (not the pad) and the back of the caliper body. Compress slowly over 30-60 seconds to allow fluid to return to master cylinder. Watch the brake fluid reservoir - it should rise but not overflow. If resistance is excessive or piston won't compress, check for seized piston requiring caliper replacement.
   ⚠Verify brake fluid reservoir cap is loose or removed to allow fluid return. A sealed reservoir can prevent piston compression or cause seal damage.
8. 8

   Install new pad hardware and brake pads
   Install new or cleaned anti-rattle clips and hardware into the caliper bracket, ensuring they are fully seated in their grooves. Apply a thin film of silicone brake grease to the pad backing plate edges where they contact the bracket (do NOT get grease on friction material or rotor surface). Install the new inboard and outboard brake pads into the bracket, ensuring they are properly positioned in the hardware clips. Pads should move slightly in the bracket but be retained by clips.
9. 9

   Reinstall caliper over new pads
   Remove the caliper from its supported position. Carefully guide the caliper down over the new brake pads and onto the bracket, ensuring the caliper piston and body properly align with the pads. The caliper should slide down easily - if excessive force is required, check for proper piston compression and pad alignment. Align the caliper slide pin bolt holes with the bracket.
10. 10

    Install and torque caliper slide pin bolts
    Clean the threads of both caliper slide pin bolts with brake cleaner. Apply a small amount of silicone brake grease to the smooth portion of the bolt that contacts the rubber boot (not the threads). Install both slide pin bolts by hand, ensuring they thread smoothly without cross-threading. Torque both bolts to specification using a torque wrench. Verify caliper can slide smoothly on pins after torquing.
    ⚠Improper torque on slide pins can cause uneven pad wear or binding. Always use a torque wrench.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
11. 11

    Repeat procedure for opposite side
    Perform steps 1 through 10 on the opposite front wheel. It is critical that both front wheels have new pads installed together to ensure balanced braking performance. Verify both calipers are properly secured and all hardware is correctly installed before proceeding.
12. 12

    Reinstall wheels and torque lug nuts
    Clean the wheel mounting surface and hub face with wire brush to ensure proper seating. Install both front wheels, threading lug nuts by hand to prevent cross-threading. Lower vehicle partially so wheels contact ground but vehicle weight is not fully on suspension. Torque lug nuts to specification in a star/cross pattern (not circular) using torque wrench. Make at least two complete passes in the star pattern to ensure even seating. Lower vehicle completely and remove jack stands.
    ⚠️Improperly torqued lug nuts can cause wheel separation while driving, resulting in loss of control and severe accidents. Always use proper torque and star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
13. 13

    Restore brake pedal pressure
    With vehicle still OFF and in PARK, slowly pump the brake pedal 10-15 times until it becomes firm. The pedal will initially go to the floor as the pistons move out to contact the new pads. Continue pumping until pedal height and firmness return to normal. Check brake fluid reservoir level and top off to MAX line with fresh DOT 4 fluid if needed. Replace reservoir cap securely.
14. 14

    Perform brake pad bedding procedure
    New brake pads require proper bedding to achieve optimal performance and prevent uneven wear. From 40 mph, perform 8-10 moderate stops (50% pedal pressure) with 30-second intervals between stops to allow cooling. Avoid complete stops - slow to 10 mph then accelerate. Then perform 3-4 harder stops from 50 mph (80% pedal pressure) with 1-minute cooling intervals. Avoid aggressive braking for the first 200 miles. Note: The EDV 500 regenerative braking may require you to disable or reduce regen to properly bed friction brakes.
    ⚠Perform bedding procedure in a safe area with no traffic. Avoid overheating brakes by allowing cooling time between stops. Smoking or brake odor is normal during bedding.

Reassembly

1. Ensure both caliper slide pin bolts are properly torqued on both sides
2. Verify wheel lug nuts are torqued in star pattern on both wheels
3. Confirm brake pedal is firm and does not sink slowly when depressed
4. Check brake fluid level is at MAX line and reservoir cap is secure
5. Exit service mode and restore normal vehicle operation if service mode was activated

Verification

• With vehicle running, press brake pedal firmly - it should feel solid and not sink. If pedal feels spongy or travels too far, there may be air in the system requiring professional bleeding.
• In a safe area at low speed (under 10 mph), test brakes to verify they engage smoothly without pulling to one side or making abnormal noises (light scraping is normal for first few stops with new pads).
• After bedding procedure, verify no brake warning lights are illuminated on dashboard.
• Re-check wheel lug nut torque after driving 50-100 miles as wheels can settle.
• Within first 200 miles, verify no brake fluid leaks are present at caliper connections or master cylinder. Check brake fluid level - it should not drop noticeably.
• Monitor brake performance for first several driving cycles. Braking should be smooth, even, and responsive without vibration, pulling, or noise (beyond normal initial pad break-in sounds).

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