Brake Rotors - Front Pair

Replace both front brake rotors on a 2024 Rivian EDV 500 electric delivery van, including proper caliper support and brake system verification.

Warnings

Tools required

Parts

• Front brake rotor × 2 — Use OEM Rivian specification
• Brake hardware kit (clips and shims) × 1 — Use OEM specification if available

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack at designated front jacking point
5. Support vehicle on jack stands at designated front lift points - verify stability
6. Remove front wheels completely and set aside
7. Inspect brake fluid reservoir level - mark current level for reference

Procedure

1. 1

   Inspect existing rotors and measure wear
   Visually inspect current rotors for cracks, deep scoring, or heat damage. If available, measure rotor thickness with micrometer and compare to minimum specification stamped on rotor hat. Document condition for comparison after installation.
2. 2

   Retract electric parking brake if equipped on front
   If vehicle is equipped with electric parking brake on front axle (verify configuration), use scan tool to enter service mode and retract parking brake actuators. If mechanical parking brake or rear-only system, proceed to next step. Some Rivian EDV configurations may not have front electric parking brake.
3. 3

   Remove caliper mounting bolts
   Using 17mm socket, remove the two caliper slide bolts that secure the brake caliper to the bracket. Support the caliper weight while removing the second bolt. Do not let caliper hang by brake hose.
4. 4

   Support brake caliper
   Carefully lift caliper off rotor and brake pads. Use wire, bungee cord, or zip ties to suspend caliper from suspension component or frame. Ensure no tension or stress is placed on brake hose. Never allow caliper to hang freely by the brake line.
   ⚠Do not depress brake pedal while caliper is removed or pistons will extend and may eject from caliper bore.
5. 5

   Remove brake pads and hardware
   Remove brake pads from caliper bracket. Remove any anti-rattle clips, shims, or hardware from the bracket. Keep pads if they will be reused; discard if replacing. Note orientation of all hardware for reinstallation.
6. 6

   Remove caliper bracket bolts
   Using 18mm socket, remove the two large caliper bracket bolts that secure the bracket to the steering knuckle. These bolts are typically torqued to high specification and may require significant force. Keep bolts clean and inspect threads for damage.
7. 7

   Remove brake rotor
   Pull rotor straight off the wheel hub. If rotor is stuck due to corrosion, use penetrating oil and allow to soak, then tap rotor from behind with rubber mallet. Some rotors have threaded holes for jacking screws - use appropriately sized bolts to press rotor off hub if necessary. Do not strike rotor face directly.
8. 8

   Clean hub surface and inspect
   Use wire brush to thoroughly clean hub face, removing all rust, corrosion, and debris. Hub surface must be clean and flat for proper rotor seating. Inspect wheel bearing for play or noise by attempting to rock hub - any movement indicates bearing wear requiring separate service. Apply thin coat of anti-seize to hub face (avoid threaded areas).
9. 9

   Install new brake rotor
   Remove protective coating from new rotor using brake parts cleaner - wipe both friction surfaces thoroughly. Slide new rotor onto hub, ensuring it seats flush against hub face. Use lug nut(s) to temporarily hold rotor in place during bracket installation. Verify rotor directional markings if applicable (some rotors are side-specific).
10. 10

    Reinstall caliper bracket
    Position caliper bracket over rotor and align mounting holes with knuckle. Install both 18mm bracket bolts and hand-tighten. Torque bracket bolts to manufacturer specification in crossing pattern. Without factory torque specs, typical specification is 125-135 ft-lbs, but you MUST verify this with Rivian service information before final tightening.
    ⚠️Caliper bracket bolt torque is CRITICAL to brake safety. Do not guess - obtain proper torque specification from factory service manual or Rivian service center before proceeding.
11. 11

    Install brake hardware and pads
    Install new or cleaned anti-rattle clips and hardware into caliper bracket per original orientation. Apply thin film of brake lubricant to pad backing plate contact points (not friction surface). Install brake pads into bracket with friction material facing rotor.
12. 12

    Compress caliper pistons
    Before reinstalling caliper, pistons must be compressed to accommodate new, thicker rotors. Use brake caliper piston tool or large C-clamp to slowly compress pistons fully into caliper bore. Monitor brake fluid reservoir - fluid level will rise as pistons compress. Remove fluid with turkey baster if level approaches MAX line to prevent overflow.
    ⚠Compressing pistons forces brake fluid back into reservoir. Do not allow reservoir to overflow as brake fluid damages paint and is toxic.
13. 13

    Reinstall brake caliper
    Remove caliper from support wire. Position caliper over brake pads and align mounting holes with caliper bracket slides. Install both 17mm caliper slide bolts and hand-tighten. Torque to manufacturer specification - typical specification is 25-35 ft-lbs, but verify with factory service information. Ensure caliper moves freely on slides after tightening.
14. 14

    Repeat process for opposite side
    Complete identical procedure for opposite front wheel. Replace both rotors as a pair to ensure even braking performance. Verify all hardware is properly installed and all bolts are torqued before proceeding.

Reassembly

1. Reinstall front wheels and hand-tighten lug nuts in star pattern
2. Remove jack stands and carefully lower vehicle to ground
3. Torque wheel lug nuts to specification (typically 150 ft-lbs for Rivian, verify with owner's manual) in star pattern
4. Reconnect 12V auxiliary battery negative terminal
5. If electric parking brake was retracted via scan tool, exit service mode and verify parking brake function

Verification

• Before starting vehicle: Pump brake pedal repeatedly (15-20 times) until firm pedal is achieved - this reseats caliper pistons against new rotors
• Check brake fluid reservoir level and top off with DOT 4 fluid to proper level if needed
• Start vehicle and verify brake system warning lights extinguish after self-test
• Test parking brake engagement and release multiple times to verify proper operation
• Perform low-speed brake test in safe area (5-10 mph) to verify brake function before driving on road
• Perform controlled stops from 30-40 mph to bed in new rotors - expect reduced braking efficiency for first 50-100 miles during break-in period
• Listen for any abnormal noises (grinding, squealing, clicking) that may indicate improper installation
• After 50 miles of driving, re-check wheel lug nut torque and verify no brake fluid leaks at calipers
• Schedule professional verification if any unusual pedal feel, noise, or vibration is experienced

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