Complete disassembly, cleaning, inspection, and rebuild of front brake calipers on a 2024 Rivian EDV 500, including replacement of seals, dust boots, and internal components.

Warnings

Tools required

Parts

• Front brake caliper rebuild kit (includes pistons, seals, dust boots, bleeder screws) × 2 — Use OEM Rivian specification
• Brake caliper mounting hardware kit × 1 — Use OEM specification
• Copper crush washers for brake lines × 2 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes for system shutdown
4. Loosen front wheel lug nuts while vehicle is on ground
5. Raise front of vehicle with floor jack and support securely on jack stands at designated lift points
6. Remove front wheels completely
7. Place brake fluid catch container under work area
8. Verify brake fluid reservoir level and mark for reference
9. Photograph caliper assembly and brake line routing before disassembly
10. Ensure adequate lighting and ventilation in work area

Procedure

1. 1

   Remove caliper from vehicle
   Carefully clean area around brake line connection to prevent contamination. Using appropriate wrench, disconnect brake line from caliper while holding caliper-side fitting to prevent twisting. Immediately cap or plug brake line to prevent fluid loss and contamination. Remove caliper mounting bolts and carefully remove caliper from brake rotor and mounting bracket. Place caliper on clean work surface with brake line connection facing up to minimize fluid loss.
2. 2

   Remove brake pads and hardware
   Remove brake pads from caliper if still attached. Remove any anti-rattle clips, shims, or pad retaining hardware. Set aside hardware and inspect for damage or excessive wear. Note orientation and position of all components for reassembly reference.
3. 3

   Remove caliper pistons
   Place shop towels or wooden blocks inside caliper to catch pistons. If using compressed air method, gradually apply low pressure (15-25 PSI maximum) to brake fluid inlet port to push pistons out. Keep fingers clear of piston path. If pistons are seized, use piston removal tool to carefully extract. For multi-piston calipers, remove one piston at a time by blocking others with wooden spacers. Inspect pistons for scoring, pitting, or chrome damage - damaged pistons must be replaced.
4. 4

   Remove dust boots and seals
   Carefully pry out dust boots from caliper housing grooves using plastic pick or wooden tool. Avoid damaging groove surfaces. Remove square-cut piston seals from caliper bore grooves using plastic pick, working carefully around entire circumference. Inspect caliper bores for any damage, scoring, or corrosion. Minor surface stains are acceptable, but deep pitting or scoring requires caliper replacement.
5. 5

   Remove bleeder screws and clean caliper body
   Remove bleeder screws from caliper body and inspect threads. Replace if damaged or corroded. Thoroughly clean all caliper components using brake parts cleaner (non-petroleum based solvent only). Use soft brass brush to clean caliper bores, being careful not to damage sealing surfaces. Clean all fluid passages and ensure no debris remains. Dry completely with compressed air or lint-free cloths.
6. 6

   Inspect and measure caliper components
   Carefully inspect caliper bore surfaces for any pitting, scoring, rust, or corrosion that cannot be cleaned. If available, measure bore diameter with precision tools and compare to manufacturer specifications. Inspect piston contact surfaces and seal grooves for damage. Any significant damage requires caliper replacement rather than rebuild. Verify rebuild kit contains correct components for this caliper.
7. 7

   Install new piston seals
   Lightly coat caliper bores with clean DOT 4 brake fluid. Remove new square-cut piston seals from rebuild kit packaging. Carefully install seals into caliper bore grooves, ensuring they seat completely and evenly around entire circumference. Do not stretch or twist seals excessively during installation. Verify seals are properly seated in grooves with no protruding sections.
8. 8

   Install pistons
   Coat new or cleaned pistons liberally with clean DOT 4 brake fluid. Carefully align piston with bore opening and gently push into bore by hand, ensuring piston enters straight without cocking. Apply steady, even pressure until piston bottoms in bore. Rotate piston slightly during installation if needed to help seal seat properly. Repeat for all pistons in caliper. Pistons should move smoothly without binding.
9. 9

   Install dust boots
   Install new dust boots from rebuild kit onto piston grooves first, ensuring boot seats properly in piston groove. Then carefully stretch boot lip over caliper housing and seat into caliper body groove. Work around circumference ensuring boot is evenly seated with no twisted or pinched sections. Boot should seal completely around piston and caliper body.
10. 10

    Install bleeder screws and prepare caliper for installation
    Install new bleeder screws from rebuild kit with light coating of brake caliper grease on threads. Do not overtighten - snug only until seated. Clean any excess fluid or grease from caliper exterior. Apply thin coat of high-temperature brake caliper grease to caliper slide pins or guide pins if applicable. Ensure all fluid passages are clear.
11. 11

    Install caliper onto vehicle
    Install new copper crush washers on brake line fitting. Position rebuilt caliper onto mounting bracket and align with brake rotor. Install caliper mounting bolts and tighten per manufacturer specification (torque values not available in database - refer to Rivian service manual). Reconnect brake line to caliper using new copper washers, tightening to prevent leaks but avoiding overtightening that could damage fitting.
12. 12

    Install brake pads and hardware
    Install brake pad hardware, shims, and anti-rattle clips in correct positions as noted during disassembly. Apply thin layer of high-temperature brake grease to pad backing plates where they contact caliper and hardware (avoid getting grease on friction surfaces or rotors). Install brake pads into caliper in correct orientation.
13. 13

    Bleed brake system
    Fill brake fluid reservoir to proper level with fresh DOT 4 brake fluid. Attach bleeder hose to caliper bleeder screw with other end submerged in clean container. Open bleeder screw 1/4 to 1/2 turn. Have assistant slowly press brake pedal to floor, or use vacuum pump to draw fluid through system. Close bleeder before pressure is released. Repeat until fluid flows with no air bubbles. Maintain reservoir level throughout process. Tighten bleeder screw when complete.
14. 14

    Repeat process for opposite side
    Perform steps 1-13 for the opposite front caliper, working carefully and methodically. Maintain cleanliness throughout process. After both calipers are rebuilt and bled, perform final brake system bleeding starting with wheel furthest from master cylinder (typically passenger rear, then driver rear, passenger front, driver front).
15. 15

    Final system check and bedding
    Verify brake fluid reservoir is at proper level. Check all brake line connections for leaks. Reinstall wheels and torque lug nuts to specification. Lower vehicle to ground. With vehicle stationary, pump brake pedal multiple times until firm pedal is achieved. Check pedal feel - should be firm with no sponge or excessive travel. Test drive in safe area at low speed to verify brake operation before normal use. Perform proper brake pad bedding procedure per manufacturer recommendations.

Reassembly

1. Torque all fasteners to manufacturer specifications using service manual (specifications not available in this database)
2. Ensure all brake line connections are tight and leak-free
3. Verify brake fluid level is at maximum fill line in reservoir
4. Double-check that all tools and materials are removed from wheel wells
5. Ensure wheel lug nuts are properly torqued in star pattern

Verification

• With vehicle running, pump brake pedal several times - pedal should be firm and not sink to floor
• Inspect all brake line connections for fluid leaks with system pressurized
• Check brake fluid reservoir level - should be at maximum line with no visible air in fluid
• Test drive vehicle in safe area at low speeds (under 25 mph) to verify brake function and pedal feel
• Verify no brake warning lights are illuminated on dashboard
• Listen for unusual noises during brake application (grinding, squealing may indicate problems)
• Test emergency brake function and verify ABS operation if possible in safe environment
• Perform 30-50 moderate brake applications from 30-40 mph to properly bed new seals and components
• Re-check all mounting hardware torque after test drive
• Re-verify brake fluid level after test drive and top off if necessary

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