This procedure covers the removal and replacement of a single front brake rotor on a 2024 Rivian EDV 500, including caliper removal and proper brake system handling.

Warnings

Tools required

Parts

• Front brake rotor × 1 — Use OEM Rivian specification
• Brake rotor set screw (if equipped) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. If replacing rotor due to wear, verify that the opposite side rotor is within acceptable thickness specifications to ensure balanced braking
4. Loosen front wheel lug nuts while vehicle is still on ground (do not remove)
5. Locate proper jacking point per Rivian service manual (typically front subframe jacking pad)
6. Raise vehicle using floor jack and immediately secure with jack stands rated for at least 5 tons
7. Remove wheel and tire assembly completely
8. Inspect brake system for any leaks, damaged lines, or worn components before proceeding

Procedure

1. 1

   Access brake fluid reservoir and prepare for caliper retraction
   Open the hood and locate the brake fluid reservoir. Remove the reservoir cap carefully to prevent vacuum buildup when retracting the caliper piston. Check fluid level and condition. If fluid is dark or contaminated, consider a full brake fluid flush. Place a clean rag under the reservoir to catch any overflow that may occur when compressing the caliper piston.
2. 2

   Remove brake caliper mounting bolts
   Locate the two caliper slide pin bolts or caliper bracket bolts on the rear of the caliper assembly. Using the appropriate socket (typically 18mm or Torx T50), remove both caliper mounting bolts completely. Support the caliper with one hand as you remove the second bolt to prevent it from falling. Note: Rivian may use slide pin bolts that require loosening but not complete removal, or bracket bolts that require full removal. Verify which type your vehicle uses.
   ⚠Do not let the caliper hang by the brake hose. This can damage the hose and cause brake failure.
3. 3

   Remove and secure brake caliper
   Carefully lift the brake caliper off the rotor and caliper bracket. Use a caliper hanger, bungee cord, or mechanic wire to secure the caliper to the suspension or chassis above. Ensure the brake hose has no tension or kinking. Do not disconnect the brake hose unless replacing the caliper.
   ⚠Never allow the caliper to hang freely by the brake hose. This will damage the internal structure of the hose.
4. 4

   Remove caliper bracket (if necessary)
   If your rotor is retained by the caliper bracket, you must remove it. Locate the two caliper bracket mounting bolts (typically larger than slide pin bolts, often 15-19mm). Remove both bracket bolts and set aside the bracket. Keep all hardware organized. Note: Some Rivian configurations may allow rotor removal without bracket removal if there is sufficient clearance.
   ℹ️Caliper bracket bolts are typically torqued to higher specifications than slide pins. Record which bolts came from which location.
5. 5

   Remove brake rotor retaining hardware
   Locate any rotor set screws or clips that retain the rotor to the hub. These are typically small Phillips or Torx screws on the rotor face. Remove and discard if worn (they are often one-time use). If the screw is seized, use penetrating oil and allow to soak. On commercial vehicles like the EDV, there may not be a retaining screw.
6. 6

   Remove old brake rotor
   Attempt to pull the rotor straight off the hub. If the rotor is stuck due to corrosion, tap the rotor from behind with a rubber mallet while rotating it. Strike evenly around the circumference, not just in one spot. If severely stuck, spray penetrating oil on the hub-to-rotor interface and wait 10-15 minutes. Do not strike the rotor face as this can cause cracking.
   ⚠Brake rotors are heavy (especially on commercial EVs). The EDV front rotor may weigh 25-35 lbs. Use proper lifting technique to avoid injury.
7. 7

   Clean and inspect hub mounting surface
   Using a wire brush and brake parts cleaner, thoroughly clean the wheel hub surface where the rotor mounts. Remove all rust, corrosion, and debris. The mating surface must be completely clean and smooth to prevent rotor runout and vibration. Inspect the wheel hub for damage, excessive wear, or loose wheel bearings. Check that wheel studs are not damaged.
8. 8

   Install new brake rotor
   Remove any protective coating from the new rotor using brake parts cleaner (both sides). Place the new rotor onto the hub, ensuring it sits completely flush against the hub face. Rotate the rotor to verify it is fully seated. If equipped with a rotor set screw hole, install a new set screw and tighten snugly (hand tight plus 1/4 turn) to hold rotor in position during reassembly.
   ℹ️New rotors have a protective oil coating that must be removed completely with brake cleaner to prevent brake contamination and reduced stopping power.
9. 9

   Reinstall caliper bracket
   If the caliper bracket was removed, reinstall it over the rotor and align with the mounting holes on the steering knuckle. Install both bracket mounting bolts and tighten in a cross pattern. Without manufacturer torque specifications, tighten firmly to approximately 80-100 ft-lbs for a vehicle of this weight class, but note that proper torque specifications should be obtained from Rivian service documentation.
   ⚠️Caliper bracket bolts are critical safety fasteners. Without verified torque specifications, this repair should be performed by a professional with access to manufacturer data.
10. 10

    Retract brake caliper piston
    Before reinstalling the caliper, the piston must be retracted to accommodate the new (thicker) rotor. Using a C-clamp or brake caliper piston tool, slowly compress the piston back into the caliper bore. Place the clamp against the back of the piston and the rear of the caliper body. Compress slowly and watch the brake fluid reservoir for overflow. If fluid reaches the MAX line, remove some fluid with a turkey baster or fluid pump.
    ⚠If the vehicle is equipped with electronic parking brake integrated into the rear calipers, do not manually compress those pistons. This procedure is for front brakes only.
11. 11

    Reinstall brake caliper
    Remove the caliper from its hanger and position it over the new rotor and bracket. Align the caliper mounting holes with the slide pins or bracket holes. Install both caliper bolts and tighten in a cross pattern. Without manufacturer specifications, tighten slide pin bolts to approximately 25-35 ft-lbs. Apply medium-strength thread locker if specified by manufacturer. Verify the caliper moves freely if it is a floating caliper design.
    ⚠️Caliper mounting bolts are critical safety fasteners. Obtain proper torque specifications from Rivian before completing this repair, or have this step verified by a professional.
12. 12

    Reinstall wheel and torque lug nuts
    Reinstall the wheel onto the hub, ensuring it seats properly. Install all lug nuts by hand first. Lower the vehicle partially so the tire contacts the ground but most weight is still on the jack stands. Tighten lug nuts in a star pattern to proper torque specification (typically 140-150 ft-lbs for a vehicle of this weight, but verify with Rivian documentation). Fully lower vehicle and remove jack stands. Perform final lug nut torque check in star pattern on the ground.
    ⚠️Improper lug nut torque can cause wheel detachment. Always use a calibrated torque wrench and follow star pattern tightening sequence.

Reassembly

1. Reinstall the brake fluid reservoir cap securely
2. Check brake fluid level and top off with DOT 4 brake fluid to the MAX line if needed
3. Pump the brake pedal several times until firm before moving the vehicle
4. Verify that the brake pedal becomes firm after 2-3 pumps - if not, there may be air in the system or improper reassembly

Verification

• Before driving, pump brake pedal 5-10 times and verify firm pedal feel returns
• Start the vehicle and press the brake pedal - it should feel firm and not sink to the floor
• Check for any brake fluid leaks around the caliper and brake lines
• Perform a low-speed brake test (5-10 mph) in a safe area to verify proper brake operation
• Listen for any abnormal noises such as grinding or squealing during initial brake applications
• Verify the vehicle stops straight without pulling to either side
• Properly bed in the new rotor following manufacturer recommendations: typically 10-15 moderate stops from 40 mph with cooling periods between stops, avoiding hard braking for the first 200 miles
• Recheck lug nut torque after driving 50-100 miles
• Monitor brake performance for the first several days and report any abnormalities immediately

More procedures for this vehicle