Brake Caliper - Front

Remove and replace the front brake caliper on a 2023 Rivian EDV 500, including brake line disconnection, bleeding, and torque-critical reassembly.

Warnings

Tools required

Parts

• Front brake caliper assembly × 1 — Use OEM Rivian specification
• Copper crush washers for banjo bolt × 2 — Use OEM specification - 2 required per banjo bolt
• Threadlocker (medium strength) × 1 — Loctite 243 or equivalent
• Brake cleaner spray × 1 — Non-chlorinated brake cleaner

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake (set to rear wheels only for front brake work).
2. Place wheel chocks behind rear wheels.
3. Open hood and disconnect 12V battery negative terminal. Wait 2 minutes for system capacitors to discharge.
4. Loosen front wheel lug nuts 1/2 turn while vehicle is on ground.
5. Raise front of vehicle with floor jack at designated front lift points (consult owner's manual for exact locations).
6. Support vehicle with heavy-duty jack stands rated for at least 5 tons per stand.
7. Remove front wheel completely.
8. Verify parking brake is NOT applied to front wheels (EDV 500 uses rear electronic parking brake).
9. Inspect brake rotor, pads, and brake line for additional damage that may require repair.
10. Have clean catch pan positioned under brake caliper area.

Procedure

1. 1

   Clean brake line connection area
   Spray brake cleaner around the banjo bolt connection where the brake line attaches to the caliper. Use a wire brush to remove any corrosion or debris from the banjo bolt and surrounding area. This prevents contamination when opening the brake system.
2. 2

   Disconnect brake line from caliper
   Place catch pan directly under the banjo bolt connection. Using a 17mm flare nut wrench, carefully loosen and remove the banjo bolt connecting the brake line to the caliper. Brake fluid will drain out - allow it to flow into the catch pan. Remove the banjo bolt completely and set aside the old copper crush washers (these MUST be replaced). Immediately plug the brake line opening with a rubber cap or clean rag to minimize fluid loss and contamination.
   ⚠Do NOT reuse the old copper crush washers. Reusing washers will cause brake fluid leaks and potential brake failure.
3. 3

   Remove caliper bracket bolts
   Locate the two caliper bracket bolts that secure the caliper assembly to the steering knuckle. These are large bolts accessible from the rear of the caliper. Using an 18mm socket and breaker bar, loosen both caliper bracket bolts. These bolts are torqued to 120 Nm and may require significant force to break free. Remove both bolts completely.
4. 4

   Remove caliper assembly
   With both bracket bolts removed, carefully lift the entire caliper assembly away from the brake rotor and steering knuckle. The caliper will be free at this point. Inspect the wheel speed sensor connector (if equipped on front caliper) and disconnect carefully if present. Place the old caliper aside on a clean work surface.
5. 5

   Inspect mounting surfaces
   Thoroughly clean the caliper mounting surface on the steering knuckle using a wire brush and brake cleaner. Remove all corrosion, rust, and old threadlocker from the bolt holes. Inspect threads in the knuckle for damage. Check that the brake rotor surfaces are clean and free of excessive rust or scoring that would require rotor replacement.
6. 6

   Prepare new caliper
   Unpack the new brake caliper and verify it matches the old unit exactly. Remove any protective shipping caps or plugs from the brake line port. Verify the bleeder screw moves freely (do not remove, just verify it turns slightly). If applicable, connect the wheel speed sensor connector to the new caliper.
7. 7

   Apply threadlocker to bracket bolts
   Clean the threads of both caliper bracket bolts with brake cleaner. Apply a thin, even coat of medium-strength threadlocker (Loctite 243 or equivalent) to the threaded portion of both bolts. Do not apply threadlocker to the first 2-3 threads to prevent it from entering the knuckle threads.
8. 8

   Install new caliper to knuckle
   Position the new caliper assembly over the brake rotor and align the bracket bolt holes with the threaded holes in the steering knuckle. Insert both caliper bracket bolts by hand and thread them in several turns to ensure proper thread engagement. Once both bolts are hand-tight, use the torque wrench and 18mm socket to tighten both bolts in a cross-pattern to the specified torque.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
9. 9

   Reconnect brake line with new washers
   Remove the plug or rag from the brake line. Install one NEW copper crush washer onto the banjo bolt, then position the brake line banjo fitting onto the caliper port. Install the second NEW copper crush washer on the other side of the banjo fitting. Thread the banjo bolt by hand through the washers and into the caliper port until finger-tight. Verify the brake line is not twisted or kinked.
   ⚠️CRITICAL: You MUST use two NEW copper crush washers. Failure to replace washers will cause brake fluid leakage and complete brake failure.
   Torque spec

   Brake Line Banjo Bolt25 Nm (18 lb-ft)
10. 10

    Torque banjo bolt to specification
    Using the torque wrench and 17mm wrench, tighten the banjo bolt to exactly 25 Nm (18 lb-ft). Do not overtighten - the copper washers are designed to crush and seal at this specific torque. After torquing, visually verify the brake line sits properly without stress or kinking.
    Torque spec

    Brake Line Banjo Bolt25 Nm (18 lb-ft)
11. 11

    Bleed the brake caliper
    Locate the bleeder screw on the top rear of the new caliper. Attach clear tubing to the bleeder screw and route the other end into a catch bottle. Have an assistant pump the brake pedal 5-6 times and hold pressure. Open the bleeder screw 1/2 turn using an 8mm wrench while the pedal is held down. Allow fluid and air to escape into the tubing. Close the bleeder screw before the pedal reaches the floor. Repeat this process until no air bubbles appear in the fluid stream (typically 5-10 cycles). Check the master cylinder reservoir frequently and maintain fluid level above MIN mark.
    ⚠Never allow the master cylinder reservoir to run empty during bleeding or air will enter the entire system.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
12. 12

    Final bleeder screw torque
    After bleeding is complete with no air bubbles visible, close the bleeder screw while the brake pedal is held down. Use the torque wrench to tighten the bleeder screw to 10 Nm (7 lb-ft). Do not overtighten as this can strip the threads or crack the caliper body. Remove the bleeding tubing.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
13. 13

    Reinstall wheel and lower vehicle
    Clean the wheel hub face and mounting surface. Reinstall the front wheel, threading all lug nuts by hand. Tighten lug nuts in a star pattern to snug with the vehicle still raised. Lower the vehicle to the ground using the jack. Once on the ground, torque all lug nuts to Rivian specification (consult owner's manual for exact torque, typically 180-200 Nm for EDV) in a star pattern.

Reassembly

1. Verify all brake line connections are tight and show no signs of leakage.
2. Confirm master cylinder brake fluid level is at MAX mark with DOT 4 fluid.
3. Inspect the entire front brake assembly for proper installation and clearance.
4. Ensure no tools or parts were left in the wheel well area.

Verification

• With the vehicle still off the ground, spin the front wheel by hand to verify the brake rotor rotates freely without dragging or rubbing sounds.
• Reconnect the 12V battery negative terminal.
• Start the vehicle and allow the brake system to initialize (warning lights should extinguish after a few seconds).
• With the engine running, pump the brake pedal several times - it should feel firm and consistent. If the pedal is soft or spongy, additional bleeding is required.
• Inspect the banjo bolt connection and bleeder screw for any brake fluid seepage. Wipe dry and check again after 5 minutes.
• Perform a low-speed brake test in a safe area (under 10 mph) to verify proper brake function before normal driving.
• Test drive at gradually increasing speeds in a safe area, verifying straight-line braking with no pulling to either side.
• After the first 50 miles of driving, re-inspect all brake connections for leaks and verify torque on caliper bracket bolts and wheel lug nuts.
• If the ABS warning light illuminates or brake pedal feel is abnormal, DO NOT DRIVE the vehicle - seek immediate professional service.

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