Brake Pads and Rotors - Front

Replace front brake pads and rotors on a 2023 Rivian EDV 500 electric delivery van, including caliper service and proper bedding procedure.

Warnings

Tools required

Parts

• Front brake pad set (includes hardware) × 1 — Use OEM Rivian specification
• Front brake rotors (pair) × 2 — Use OEM Rivian specification
• Brake caliper slide pin grease × 1 — High-temperature silicone brake grease

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake. Place transmission in Park.
2. Chock the rear wheels securely on both sides to prevent vehicle movement.
3. Access the vehicle settings through the center display or Rivian app and enable Service Mode if available to disable regenerative braking and prepare brake system for service.
4. Locate brake fluid reservoir in engine compartment and use turkey baster to remove approximately 2-3 ounces of fluid to prevent overflow when compressing caliper pistons. Dispose of old fluid properly.
5. Loosen front wheel lug nuts (19mm) one full turn while vehicle is still on ground.
6. Lift front of vehicle using floor jack at designated front lift point, then secure with jack stands at proper jacking points per owner's manual.
7. Remove front wheels completely and set aside.
8. Inspect brake system for any signs of brake line damage, leaking fluid, or caliper abnormalities before proceeding.

Procedure

1. 1

   Remove caliper slide pin bolts
   Locate the caliper assembly. Identify the two caliper slide pins (typically 15mm bolts) on the rear of the caliper. Clean around the slide pins with brake cleaner. Using a 15mm socket, remove the lower caliper slide pin bolt first, then the upper slide pin bolt. Keep these bolts in a clean location as they will be reused.
2. 2

   Remove caliper from rotor
   Carefully pivot the caliper upward and away from the rotor. Do NOT let the caliper hang by the brake hose as this can damage the hose. Use wire or a bungee cord to hang the caliper from the suspension or chassis, ensuring no strain is placed on the brake line. Inspect the brake hose for any cracks, chafing, or damage.
3. 3

   Remove old brake pads
   Remove the old brake pads from the caliper bracket. Note the orientation of any anti-rattle clips, shims, or pad wear sensors. Remove and discard all old pad hardware. Inspect the caliper bracket for excessive wear or damage.
4. 4

   Remove caliper bracket bolts
   Using an 18mm socket, remove the two caliper bracket bolts that secure the bracket to the steering knuckle. These bolts are typically torqued to high values and may require significant force. If bolts are stubborn, apply penetrating oil and allow to soak for 10-15 minutes. Remove the caliper bracket completely.
5. 5

   Remove old rotor
   If present, remove any Torx set screws securing the rotor to the hub (these may not be reused). The rotor should slide off the wheel hub. If rotor is stuck due to corrosion, tap the rotor from behind with a rubber mallet, alternating around the rotor face. Do NOT strike the rotor friction surface. If severely stuck, spray penetrating oil around the hub pilot area and continue tapping.
6. 6

   Clean hub and prepare for new rotor
   Using a wire brush, thoroughly clean the wheel hub mounting surface, removing all rust, corrosion, and debris. The hub surface must be clean and flat for proper rotor seating. Clean the hub pilot (center ring) where the rotor centers. Apply a thin coat of anti-seize to the hub face (avoid getting any on the rotor mounting surface where possible).
7. 7

   Install new rotor
   Remove any protective coating from the new rotor using brake cleaner and clean rags. Clean both sides of the rotor thoroughly. Slide the new rotor onto the wheel hub, ensuring it seats flush against the hub face. If applicable, install a rotor set screw temporarily to hold the rotor in place during assembly (hand-tight only, this screw is not critical).
8. 8

   Reinstall caliper bracket
   Position the caliper bracket back onto the steering knuckle. Install both caliper bracket bolts and tighten in an alternating pattern. Since torque specifications are not available in the database, these bolts must be torqued to manufacturer specification (typically 125-150 ft-lbs for heavy commercial vehicles, but verify with Rivian service documentation). Ensure bracket is secure and does not move.
9. 9

   Prepare caliper piston
   With the caliper still suspended, inspect the caliper piston and dust boot for damage. Using a brake caliper piston compression tool or large C-clamp, slowly compress the caliper piston fully into the caliper bore. This will push brake fluid back into the reservoir. Compress slowly to avoid damaging seals. Ensure the piston retracts evenly and fully. Watch the brake fluid reservoir to ensure it does not overflow.
10. 10

    Install new brake pad hardware and pads
    Install new anti-rattle clips and pad hardware onto the caliper bracket per the orientation noted during disassembly. Apply a thin layer of high-temperature brake grease to the pad backing plates where they contact the caliper bracket (do NOT get grease on friction material). Install the inner and outer brake pads into the caliper bracket, ensuring they are properly seated in the hardware clips.
11. 11

    Lubricate and inspect caliper slide pins
    Remove the caliper slide pins completely from the caliper bracket. Inspect the slide pin boots for tears or damage and replace if necessary. Clean the slide pins thoroughly with brake cleaner. Apply a generous coat of high-temperature silicone brake grease to the slide pins. Reinstall the slide pins into their bores, ensuring the boots seat properly.
12. 12

    Reinstall caliper
    Lower the caliper assembly down over the new brake pads and rotor. Align the caliper slide pin bolt holes. Install both caliper slide pin bolts and tighten. Since torque specifications are not available in the database, these bolts must be torqued to manufacturer specification (typically 25-35 ft-lbs, but verify with Rivian service documentation). Ensure caliper moves freely on slide pins.
13. 13

    Repeat for opposite side
    Repeat all steps (1-12) for the opposite front wheel to replace the second rotor and brake pad set. Both front brakes must be serviced together to maintain balanced braking performance.
14. 14

    Reinstall wheels and torque lug nuts
    Reinstall both front wheels onto the hubs. Install all lug nuts and tighten by hand. Lower the vehicle until the wheels just contact the ground but the suspension is not fully loaded. Using a torque wrench and 19mm socket, torque the lug nuts to manufacturer specification (typically 140-150 ft-lbs for this vehicle weight class, but verify with owner's manual) in a star pattern. Fully lower vehicle and remove jack stands.
15. 15

    Restore brake pedal and check fluid level
    Before moving the vehicle, pump the brake pedal several times until it becomes firm. This restores hydraulic pressure to the calipers. The pedal should feel firm and not sink. Check the brake fluid reservoir and add DOT 4 brake fluid if needed to bring level to the MAX line. Exit Service Mode in vehicle settings if it was enabled.

Reassembly

1. Ensure all caliper bolts, bracket bolts, and wheel lug nuts are torqued to proper specifications per Rivian service documentation
2. Verify brake pedal feels firm and does not sink to the floor before test driving
3. Double-check that no tools or parts are left in the wheel wells or under the vehicle
4. Inspect for any brake fluid leaks around caliper connections and brake lines

Verification

• Pump brake pedal 10-15 times and verify firm pedal with no excessive travel. Pedal should not sink when held under pressure.
• Check brake fluid reservoir level is at MAX line with DOT 4 brake fluid.
• Start vehicle and verify no brake warning lights are illuminated on the instrument cluster.
• Perform initial test drive in a safe area at low speed (under 15 mph) to verify brakes engage properly and vehicle stops straight without pulling to either side.
• Perform proper brake bedding procedure: Make 6-10 moderate stops from 40-45 mph down to 15 mph with light-to-moderate pedal pressure, allowing 30 seconds between stops for brake cooling. Avoid coming to a complete stop during bedding if possible. After bedding, allow brakes to cool for 10 minutes without use.
• After bedding and cooling, perform a final test from highway speed in a safe location to verify full braking performance.
• Re-check wheel lug nut torque after 50-100 miles of driving.
• Monitor brake performance for the first few hundred miles and report any unusual noises, vibrations, or reduced braking performance to a professional immediately.

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