Brake Rotors - Front Pair

This procedure covers the removal and replacement of the front brake rotors on a 2023 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Front brake rotor × 2 — Use OEM specification or equivalent
• Brake hardware kit (if applicable) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Power down the vehicle completely using the main control screen
3. Chock the rear wheels securely on both sides
4. Locate the manufacturer-recommended jacking points in the owner's manual
5. Verify you have OEM torque specifications available, as none are included in this database yet
6. Ensure brake fluid reservoir is accessible and note current fluid level
7. Allow brake components to cool completely if vehicle was recently driven

Procedure

1. 1

   Loosen front wheel lug nuts
   With vehicle still on the ground, loosen (but do not remove) all front wheel lug nuts approximately one full turn. This prevents the wheel from spinning when elevated.
2. 2

   Raise and secure vehicle
   Using a floor jack at the manufacturer-specified front jacking point, raise the front of the vehicle until both front wheels are off the ground. Immediately place jack stands under the designated support points. Lower the vehicle onto the jack stands and verify stability before proceeding. Never rely solely on the jack.
3. 3

   Remove front wheels
   Remove the lug nuts completely and remove both front wheels. Set wheels aside in a safe location where they will not roll.
4. 4

   Inspect brake system
   Visually inspect the brake caliper, brake lines, and brake pads for damage, excessive wear, or fluid leaks. Check brake pad thickness and replace if below minimum specification. Note the routing of any ABS sensor wires or brake wear sensors.
5. 5

   Compress brake caliper piston
   Before removing the caliper, slowly compress the brake caliper piston back into its bore using a C-clamp or brake piston compressor tool. This creates clearance for the new rotor and prevents brake fluid overflow. Monitor the brake fluid reservoir and remove fluid if necessary to prevent overflow.
   ⚠Do not allow brake fluid to overflow from the reservoir as it is corrosive to paint and electrical components.
6. 6

   Remove brake caliper mounting bolts
   Locate and remove the brake caliper mounting bolts (typically two bolts on the rear of the caliper bracket). Consult factory service information for exact bolt locations and torque specifications, as none are available in this database. Carefully slide the caliper off the rotor.
7. 7

   Secure brake caliper
   Using a caliper hanger or sturdy wire, hang the brake caliper from the suspension or chassis. Never allow the caliper to hang by the brake hose, as this can damage the hose and cause brake failure.
   ⚠️Never let the brake caliper hang by the brake hose. This can cause internal hose damage and brake failure.
8. 8

   Remove caliper bracket
   Remove the caliper bracket mounting bolts that secure the bracket to the steering knuckle. These bolts are typically larger and require more torque than caliper bolts. Remove the bracket completely to access the rotor. Refer to factory specifications for bolt torque values.
9. 9

   Remove old brake rotor
   If the rotor is secured with a retaining screw or clip, remove it first. Slide the old rotor off the wheel hub. If the rotor is stuck due to corrosion, tap it gently with a rubber mallet from behind. Do not strike the rotor face. If severely corroded, apply penetrating oil and allow time to soak.
10. 10

    Clean hub mounting surface
    Using a wire brush, thoroughly clean the wheel hub mounting surface, removing all rust, corrosion, and debris. The hub face must be completely clean and smooth to ensure proper rotor seating and prevent runout. Apply brake cleaner to remove any remaining residue.
11. 11

    Prepare and install new rotor
    Remove any protective coating from the new rotor using brake cleaner. Clean both faces of the rotor thoroughly. Apply a thin coat of anti-seize compound to the hub mounting surface (not the rotor friction surface). Slide the new rotor onto the hub, ensuring it seats fully and flat against the hub face. If applicable, install any rotor retaining screws or clips.
12. 12

    Reinstall caliper bracket
    Position the caliper bracket onto the steering knuckle and install the mounting bolts. Torque the caliper bracket bolts to manufacturer specification using a torque wrench. Consult factory service information for exact torque values, as they are not available in this database. Ensure bracket is secure and properly seated.
    ⚠️Caliper bracket bolts must be torqued to exact specification. Improper torque can result in brake failure.
13. 13

    Reinstall brake caliper
    Remove the caliper from its hanger and carefully position it over the new rotor and bracket. Ensure brake pads are properly positioned on both sides of the rotor. Install the caliper mounting bolts and torque to manufacturer specification. Do not over-tighten sliding caliper bolts.
14. 14

    Repeat for opposite side
    Repeat steps 5 through 13 for the opposite front wheel, ensuring both rotors are replaced as a pair to maintain balanced braking performance.
15. 15

    Reinstall wheels and lower vehicle
    Reinstall both front wheels and hand-tighten all lug nuts in a star pattern. Raise the vehicle slightly off the jack stands using the floor jack, remove the jack stands, and carefully lower the vehicle to the ground. Once on the ground, torque the lug nuts to manufacturer specification in a star pattern using a torque wrench.

Reassembly

1. Torque all fasteners to manufacturer specifications using a calibrated torque wrench
2. Ensure brake calipers move freely on their slides or pins
3. Verify brake pad placement and caliper alignment on both sides
4. Check brake fluid level in reservoir and top off with DOT 4 brake fluid if needed
5. Do not mix different types or brands of brake fluid

Verification

• Before driving, pump the brake pedal several times until it feels firm to reseat the caliper pistons against the new rotors
• Check brake fluid level again after pumping pedal and top off if necessary
• Perform a visual inspection to ensure all components are properly installed and all tools are removed
• Test brakes at low speed in a safe area before normal driving to verify proper operation
• Perform a complete brake system bleed if the brake pedal feels spongy or soft
• Expect reduced braking performance for the first 200-300 miles during the break-in period for new rotors
• Listen for any unusual noises during brake application and inspect immediately if heard
• Verify that the brake warning lights on the dashboard are not illuminated after starting the vehicle

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