This procedure covers the removal and replacement of a single front brake rotor on a 2023 Rivian EDV 500 electric delivery van, including caliper bracket removal and proper brake system verification.

Warnings

Tools required

Parts

• Front brake rotor × 1 — Use OEM specification for Rivian EDV 500
• Brake hardware kit (optional clips and shims) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground and ensure transmission is in Park
2. Chock the rear wheels securely
3. Obtain factory torque specifications for wheel lug nuts, caliper bolts, and caliper bracket bolts from Rivian service manual before proceeding
4. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
5. Lift front of vehicle using floor jack at designated front lift point
6. Support vehicle on jack stands rated for at least 4,000 lbs each, positioned at factory jacking points
7. Remove wheel completely and set aside
8. Inspect brake system for leaks, damaged lines, or excessive wear on both sides

Procedure

1. 1

   Check brake fluid reservoir level
   Open hood and locate brake fluid reservoir. Check current fluid level and mark it. As you compress the caliper piston later, fluid level will rise. If fluid is at MAX line, remove some fluid with a turkey baster or fluid transfer pump to prevent overflow. Store removed fluid in sealed container for proper disposal.
2. 2

   Remove caliper mounting bolts
   Locate the two caliper slide bolts on the rear of the caliper assembly (typically 18mm). Remove both bolts completely while supporting the caliper with your other hand. The caliper should now pivot away from the rotor.
3. 3

   Support brake caliper
   Carefully lift the caliper off the rotor and brake pads. Support the caliper using a wire, bungee cord, or hook attached to the suspension or chassis. Ensure there is NO tension or stress on the brake hose. The caliper must hang freely without pulling on the hydraulic line.
4. 4

   Remove brake pads and hardware
   Remove the brake pads from the caliper bracket. Note the position and orientation of any anti-rattle clips, shims, or springs for reassembly. Take photos if needed. Set pads aside if reusing, or replace with new pads if worn.
5. 5

   Remove caliper bracket bolts
   Locate the two caliper bracket mounting bolts that secure the bracket to the steering knuckle (larger bolts, typically behind the bracket). These bolts are under high torque. Use penetrating oil if needed. Remove both bolts completely and remove the caliper bracket assembly from the vehicle.
6. 6

   Remove brake rotor
   The rotor should now slide off the wheel hub. If rotor is stuck due to corrosion, thread two appropriately-sized bolts into the threaded holes on the rotor face (if present) to push it off. Alternatively, tap rotor from behind with a rubber mallet while rotating. Never strike the rotor friction surface directly with metal tools.
7. 7

   Clean hub surface
   With rotor removed, clean the wheel hub mounting surface thoroughly with a wire brush to remove all rust, corrosion, and debris. The hub face must be completely clean and flat to prevent rotor runout. Clean the wheel stud threads as well.
8. 8

   Inspect wheel hub and bearings
   Inspect the wheel hub for damage, scoring, or excessive rust. Check wheel bearing for play by attempting to move the hub in and out. There should be no perceptible movement. If bearing issues are detected, the bearing must be serviced before installing new rotor.
9. 9

   Install new brake rotor
   Apply a thin coat of anti-seize compound to the hub face (avoid getting any on rotor friction surfaces). Place new rotor onto wheel hub, aligning holes with wheel studs. Thread one lug nut on temporarily to hold rotor in place during reassembly. Remove any protective coating from new rotor with brake cleaner.
10. 10

    Reinstall caliper bracket
    Position caliper bracket onto steering knuckle mounting points. Install both bracket bolts and hand-tighten. Torque bracket bolts to factory specification (obtain from Rivian service manual) in a cross pattern. These bolts are critical and must be torqued accurately.
11. 11

    Compress caliper piston
    Before installing caliper, the piston must be compressed fully into the caliper bore to accommodate the new rotor thickness. Use a brake caliper piston compressor tool or large C-clamp positioned against the piston and back of caliper. Compress slowly and watch brake fluid reservoir to ensure it does not overflow.
12. 12

    Install brake pads and hardware
    Install any anti-rattle clips or hardware onto the caliper bracket in their original positions. Install brake pads into bracket, ensuring directional pads are installed correctly (wear indicators typically face toward rear of vehicle). Verify pads move freely in bracket.
13. 13

    Reinstall brake caliper
    Remove caliper from its support. Position caliper over brake pads and rotor. Align caliper slide bolt holes with bracket. Install both caliper slide bolts and hand-tighten. Torque caliper bolts to factory specification. Remove temporary lug nut used to hold rotor.
14. 14

    Reinstall wheel and lower vehicle
    Mount wheel onto hub, aligning with studs. Install all lug nuts hand-tight in a star pattern. Lower vehicle until tire just contacts ground. Torque lug nuts to factory specification (typically 130-140 ft-lb for this vehicle) in a star pattern. Fully lower vehicle and remove jack stands.

Reassembly

1. Double-check that all caliper bolts and bracket bolts are torqued to specification
2. Verify brake caliper slide pins move freely and are properly lubricated
3. Check brake fluid level in reservoir and top off with DOT 4 brake fluid if needed to bring to MAX line
4. Ensure no tools or parts are left in wheel well area

Verification

• Before moving vehicle, pump brake pedal slowly 10-15 times until pedal feels firm and normal. The first few pumps will feel soft as the caliper piston extends to contact the new rotor.
• Check brake pedal height and feel. Pedal should be firm within first half of travel. If pedal is soft or spongy, air may be in the system and bleeding may be required.
• Inspect for any brake fluid leaks around caliper, hoses, and reservoir.
• Test drive in safe area at low speed (under 10 mph initially). Apply brakes gently multiple times to bed in new rotor and verify proper braking function.
• Perform several moderate stops from 30-40 mph to properly seat brake pads to new rotor surface.
• Listen for any unusual noises during braking. Some light squealing may occur during initial break-in period.
• After 50-100 miles, re-check wheel lug nut torque and verify no loosening has occurred.
• New rotors require 200-300 miles of normal driving to fully break in. Avoid hard braking during this period if possible.

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