Brake Caliper - Rear

This procedure covers the removal and replacement of a rear brake caliper on a 2023 Rivian EDV 500, including bleeding the brake system to ensure safe operation.

Warnings

Tools required

Parts

• Rear brake caliper assembly × 1 — Use OEM specification
• Copper crush washers for brake line banjo bolt × 2 — Use OEM specification
• Brake caliper bracket bolts (if corroded) × 2 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Power off the vehicle completely and ensure it will not enter accessory mode during service
3. Loosen rear wheel lug nuts while vehicle is on the ground
4. Safely raise and support the rear of the vehicle on jack stands at designated lift points
5. Remove the rear wheel on the side being serviced
6. Use turkey baster or fluid pump to remove approximately half the brake fluid from the master cylinder reservoir to prevent overflow when compressing caliper pistons
7. Inspect the brake system for any additional damage or wear that may require attention

Procedure

1. 1

   Support the brake caliper
   Before disconnecting the brake line, prepare to support the caliper weight. Have wire or a bungee cord ready to hang the caliper from the suspension or chassis once the mounting bolts are removed. Never let the caliper hang by the brake hose.
2. 2

   Remove brake line banjo bolt
   Place a drain pan or absorbent pads under the caliper. Using a combination wrench, carefully loosen and remove the brake line banjo bolt connecting the flexible brake hose to the caliper. Brake fluid will drain from the connection. Remove and discard both copper crush washers from each side of the banjo fitting. Immediately plug the brake line opening with a clean rubber cap or plug to minimize fluid loss and prevent contamination.
   ⚠Brake fluid will spill during this step. Protect painted surfaces and have absorbent materials ready.
3. 3

   Remove caliper bracket bolts
   Locate the two caliper bracket bolts that secure the caliper assembly to the rear suspension knuckle or mounting bracket. These are typically located on the back side of the caliper. Using the appropriate socket and breaker bar if necessary, remove both caliper bracket bolts completely. These bolts are torqued to a high specification and may require significant force to loosen.
   ⚠Caliper bracket bolts are high-torque fasteners. Ensure proper socket engagement to avoid rounding bolt heads.
4. 4

   Remove caliper assembly
   With both bracket bolts removed, carefully lift the caliper assembly away from the brake rotor and mounting bracket. The caliper should now be completely free. Remove the old caliper from the work area. Inspect the brake rotor surface for scoring, excessive wear, or damage. Inspect brake pads if they are remaining with the bracket.
5. 5

   Prepare new caliper
   Unbox the new brake caliper and verify it matches the removed unit. If the caliper pistons are fully extended, use a brake caliper piston tool or large C-clamp to carefully compress them fully into their bores. This ensures the caliper will fit over the brake pads and rotor. Clean any preservative oil from the caliper mounting surfaces with brake cleaner.
6. 6

   Install new caliper
   Position the new caliper over the brake rotor and align the mounting holes with the bracket on the suspension knuckle. Ensure the brake pads are properly seated if they remained on the bracket. Insert both caliper bracket bolts and thread them in by hand to ensure proper thread engagement before tightening.
7. 7

   Torque caliper bracket bolts
   Apply medium-strength threadlocker to the caliper bracket bolts if recommended by the service manual. Using a torque wrench, tighten both caliper bracket bolts in an alternating pattern to the specified torque of 100 Nm (74 lb-ft). Verify both bolts are properly seated and torqued.
   ⚠️CRITICAL: Caliper bracket bolts must be torqued to specification. Under-torquing can result in caliper detachment and complete brake failure.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
8. 8

   Connect brake line with new washers
   Remove the plug from the brake line. Place one NEW copper crush washer on each side of the banjo fitting (one against the caliper body, one against the banjo bolt head). Position the brake line banjo fitting into the caliper port, insert the banjo bolt, and thread it in by hand. Do not reuse old copper washers as they will not seal properly.
   ⚠️CRITICAL: New copper crush washers must be used. Reusing old washers will cause brake fluid leaks and potential brake failure.
9. 9

   Torque brake line banjo bolt
   Using a torque wrench and combination wrench to hold the brake line fitting stationary, tighten the banjo bolt to the specified torque of 25 Nm (18 lb-ft). Be careful not to twist the flexible brake hose during tightening. Verify the hose is positioned without kinks or interference with suspension components.
   ⚠️CRITICAL: Over-torquing can damage the caliper port threads; under-torquing will cause leaks. Use a torque wrench.
   Torque spec

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

    Bleed the brake caliper
    Locate the bleeder screw on the rear of the new caliper. Attach a clear tube to the bleeder screw and route the other end into a catch bottle. Have an assistant sit in the driver's seat. Refill the master cylinder reservoir to the MAX line with fresh DOT 4 brake fluid. Instruct the assistant to slowly pump the brake pedal 3-5 times and hold firm pressure. Open the bleeder screw 1/4 to 1/2 turn and observe fluid and air bubbles flowing through the tube. Close the bleeder screw before the pedal reaches the floor. Repeat this process until no air bubbles appear in the fluid stream and the brake pedal feels firm. Check and refill the master cylinder reservoir frequently to prevent introducing additional air.
    ⚠️Never allow the brake fluid reservoir to run empty during bleeding, as this introduces air into the ABS system requiring specialized equipment to bleed.
11. 11

    Torque bleeder screw
    Once bleeding is complete and the brake pedal feels firm with no air bubbles present, tighten the bleeder screw to the specified torque of 10 Nm (7 lb-ft). Do not over-tighten as the bleeder screw can be easily damaged. Remove the bleeding tube and wipe the area clean.
    ⚠Bleeder screws are easily stripped or broken. Do not exceed specified torque.
    Torque spec

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

    Inspect for leaks
    With the brake pedal still under pressure from your assistant, carefully inspect the banjo bolt connection and bleeder screw for any signs of brake fluid leakage. Wipe the entire caliper area with a clean white cloth and look for fresh fluid. If any leaks are detected, depressurize the system and re-torque or replace components as necessary.
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel, threading lug nuts by hand first to ensure proper engagement. Tighten lug nuts in a star pattern with hand tools. Lower the vehicle to the ground. With the vehicle on the ground, torque the lug nuts to manufacturer specification in a star pattern. Remove jack stands and store tools.

Reassembly

1. Top off brake fluid reservoir to the MAX line with fresh DOT 4 brake fluid
2. Ensure all tools and materials are removed from the vehicle and work area
3. Double-check that all brake line connections are secure and dry with no leaks
4. Verify the brake pedal feels firm and returns to normal height

Verification

• Start the vehicle and verify the brake warning light is not illuminated on the instrument cluster
• Pump the brake pedal several times and verify it feels firm with normal travel - it should not sink to the floor
• Perform a low-speed brake test in a safe area to verify proper brake function before returning to normal driving
• Re-inspect the caliper area after the test drive for any signs of brake fluid leakage
• If the brake pedal feels soft, spongy, or travels too far, repeat the bleeding procedure as air may still be present in the system
• Monitor brake performance closely for the first several miles of driving
• If ANY abnormal brake behavior is observed, do not drive the vehicle and seek professional assistance immediately

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle