This procedure covers the replacement of front brake pads on the 2023 Rivian EDV 500 electric delivery van, including proper brake system handling and bedding-in procedures.

Warnings

Tools required

Parts

• Front brake pad set (left and right) × 1 — Use OEM specification
• Brake hardware kit (clips and shims) × 1 — Use OEM specification
• Brake caliper slide pin lubricant × 1 — High-temperature synthetic brake grease

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, firm ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Access the vehicle's service mode through the center display: Settings > Service > Brake Service Mode. This retracts the electronic parking brake pistons and disables regenerative braking
4. Remove approximately 1/3 of brake fluid from master cylinder reservoir using turkey baster to prevent overflow when compressing caliper pistons
5. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
6. Raise front of vehicle with floor jack at designated lift points per owner's manual
7. Support vehicle securely on jack stands at manufacturer-specified support points
8. Remove front wheels completely and set aside

Procedure

1. 1

   Inspect brake system components
   With wheels removed, visually inspect brake rotors for scoring, cracking, or excessive wear. Check brake lines and hoses for damage, leaks, or corrosion. Measure rotor thickness with micrometer and compare to minimum thickness specification stamped on rotor. If rotors are below minimum thickness or severely damaged, they must be replaced before installing new pads. Check caliper slide pins for binding or corrosion.
2. 2

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper assembly. Clean debris from bolt heads. Using appropriate metric socket, remove the lower caliper slide pin bolt first, then the upper bolt. Support the caliper with one hand while removing the second bolt to prevent it from falling. Note: Some Rivian models may use a single-bolt floating caliper design; verify your specific configuration.
3. 3

   Pivot and support caliper
   Carefully pivot the caliper upward away from the rotor (or remove completely if dual-pin design). Do NOT allow the caliper to hang by the brake hose as this can damage the hose internally. Support the caliper using a wire hook, bungee cord, or by resting it on a suspension component. Ensure no strain is placed on the brake line.
4. 4

   Remove old brake pads and hardware
   Remove the old brake pads from the caliper bracket. Note the orientation and position of any anti-rattle clips, shims, or springs for proper reassembly. Remove all pad hardware clips from the caliper bracket. Inspect the bracket for wear grooves where pads slide; excessive wear grooves may require bracket replacement.
5. 5

   Clean caliper bracket and slides
   Use a wire brush to thoroughly clean the caliper bracket pad mounting surfaces, removing all rust, debris, and old lubricant. Clean the caliper slide pins and inspect their rubber boots for tears or damage. Spray brake cleaner on all surfaces and wipe clean with lint-free cloth. Inspect slide pin bores in the bracket for corrosion.
6. 6

   Compress caliper piston
   Before compressing the piston, verify the master cylinder reservoir cap is loose to allow fluid displacement. Using a C-clamp or brake caliper piston tool, slowly and evenly compress the caliper piston(s) completely into the caliper bore. Watch the master cylinder reservoir and ensure fluid does not overflow. For multi-piston calipers, compress all pistons evenly. The piston should compress smoothly; if excessive force is required or piston is seized, the caliper requires rebuild or replacement.
7. 7

   Install new brake hardware
   Install the new anti-rattle clips and hardware from the brake hardware kit onto the caliper bracket, matching the orientation of the original hardware. Ensure clips are fully seated and secure. Apply a thin layer of high-temperature brake lubricant to the pad slide contact points on the bracket (where the pad backing plates contact the bracket).
8. 8

   Install new brake pads
   Install the new brake pads into the caliper bracket, ensuring the friction material faces the rotor. The wear indicator (squealer tab) should be positioned at the top or bottom position as specified by the manufacturer (typically top inner pad). Verify pads move freely in the bracket but without excessive play. If pads include shims, ensure they are properly attached to the pad backing plates.
9. 9

   Lubricate and reinstall caliper
   Apply a thin coat of high-temperature synthetic brake grease to the caliper slide pins (do not use petroleum-based grease). Ensure slide pin boots are properly seated. Carefully lower the caliper over the new brake pads and align the slide pin holes. Thread both slide pin bolts by hand first to ensure proper alignment and prevent cross-threading.
10. 10

    Torque caliper bolts
    Using a torque wrench, tighten the caliper slide pin bolts to the manufacturer's specified torque value. Without factory torque specifications, DO NOT GUESS. Consult official Rivian service information or contact a Rivian service center for the correct torque specification. Under-torquing can allow the caliper to loosen; over-torquing can damage threads or cause binding.
    ⚠️Improper caliper bolt torque is a critical safety issue. Loose bolts can result in complete brake failure. You must obtain the correct torque specification before proceeding.
11. 11

    Repeat for opposite side
    Perform steps 1 through 10 for the opposite front wheel. Always replace brake pads on both sides of an axle simultaneously to maintain balanced braking performance. Never replace pads on only one side.
12. 12

    Reinstall wheels
    Clean wheel mounting surfaces on hubs with wire brush to remove rust and debris. Install wheels and hand-tighten lug nuts in a star pattern. Lower vehicle until wheels just contact ground but vehicle weight is not fully on wheels. Torque lug nuts to specification in star pattern (consult owner's manual for lug nut torque specification). Fully lower vehicle and remove jack stands.
13. 13

    Restore brake system and pump pedal
    Check master cylinder reservoir and top off with fresh DOT 4 brake fluid to the MAX line. Ensure reservoir cap is securely installed. Exit brake service mode through vehicle display (Settings > Service > Exit Service Mode). With vehicle off, pump the brake pedal slowly and firmly 10-15 times until pedal feels firm and consistent. Pedal should reach firm resistance before traveling more than halfway to floor.
14. 14

    Perform system reset and verification
    Using a diagnostic scan tool, clear any brake service mode codes and verify no fault codes are present in the ABS/ESC system. Start the vehicle and verify the brake warning light extinguishes. Check for any unusual noises or pedal feedback. Test parking brake electronic function to ensure proper operation.
    ⚠️Do not drive the vehicle if the brake warning light remains illuminated or if the brake pedal feels soft or travels to the floor. This indicates air in the system or a hydraulic fault requiring immediate professional service.

Reassembly

1. Torque all caliper slide pin bolts to manufacturer specification using a calibrated torque wrench
2. Torque wheel lug nuts to specification in proper star pattern sequence
3. Verify master cylinder reservoir is filled to MAX line with DOT 4 brake fluid
4. Verify all tools and materials are removed from wheel wells and under vehicle
5. Ensure brake service mode has been properly exited through vehicle display

Verification

• With vehicle running, verify brake warning light is off and no fault codes are present
• Pump brake pedal several times - it should feel firm and consistent with no excessive travel
• Perform a low-speed brake test in a safe area - vehicle should stop straight with no pulling, pulsation, or unusual noises
• Perform bed-in procedure: Make 10-15 gentle stops from 30 mph with 30-second cool-down between stops, followed by 5-10 moderate stops from 45 mph, then allow brakes to cool for 10 minutes without use
• After bed-in, perform several moderate-to-firm stops from highway speeds in a safe area to verify proper brake performance
• Re-check brake fluid level after test drive and top off if necessary
• Listen for any squealing, grinding, or clicking noises during brake application
• After 50-100 miles, re-check wheel lug nut torque and brake fluid level

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