Replace front brake pads on a 2024 Rivian EDV 500 electric delivery van, including caliper service and brake system verification.

Warnings

Tools required

Parts

• Front brake pad set (4 pads total) × 1 — Use OEM Rivian specification
• Brake hardware kit (clips and shims) × 1 — Use OEM Rivian specification
• Brake caliper guide pin grease × 1 — Synthetic brake grease

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, stable ground and ensure it is fully powered off
2. Engage parking brake and place wheel chocks behind rear wheels
3. Connect Rivian diagnostic tool and enter brake service mode to retract electronic brake system (consult service manual for exact procedure)
4. Verify high-voltage system is disabled (orange disconnect indicator visible if equipped)
5. Loosen front wheel lug nuts approximately one turn while vehicle is on ground
6. Lift front of vehicle using floor jack at designated front jacking points per owner's manual
7. Support vehicle securely on jack stands rated for vehicle weight, positioned at proper frame support points
8. Remove front wheels completely and set aside
9. Inspect brake rotors for excessive wear, scoring, or warping (minimum thickness typically marked on rotor hub)
10. Check brake fluid reservoir level and condition; remove some fluid if near maximum line to prevent overflow during piston retraction

Procedure

1. 1

   Access and inspect brake caliper
   Visually inspect the front brake caliper, rotor, and brake line connections for any damage, leaks, or unusual wear. Note the orientation of brake pad wear indicators if present. Spray brake cleaner on caliper and rotor surfaces, wiping away with clean cloth (never blow with compressed air). Verify caliper slide pins move freely by attempting to push caliper inward slightly.
2. 2

   Remove caliper bolts
   Locate the caliper mounting bolts (typically two bolts on rear of caliper, usually 18mm or 19mm). Remove the lower caliper bolt completely while supporting the caliper. Remove the upper caliper bolt while continuing to support caliper weight. Do not allow caliper to hang by brake hose. Pivot or lift caliper away from rotor and brake pads.
3. 3

   Support caliper safely
   Use a bungee cord, wire hook, or caliper hanger to support the caliper from suspension components or frame. Ensure no tension or stress is placed on the flexible brake hose. Never let caliper hang freely by the brake line as this can cause internal hose damage.
4. 4

   Remove old brake pads and hardware
   Remove the old brake pads from the caliper bracket. They may be held by clips or simply slide out. Note the position and orientation of any anti-rattle clips, shims, or pad retention hardware. Remove and discard all old brake hardware clips from the caliper bracket. Use a wire brush to clean the pad contact surfaces on the caliper bracket where pads slide.
5. 5

   Inspect caliper bracket and slides
   Thoroughly inspect caliper bracket for cracks, excessive wear on pad contact surfaces, or corrosion. Check that pad slide points are smooth. If the caliper bracket shows damage or excessive wear grooves, it must be replaced. Inspect caliper slide pins (guide pins) for corrosion, binding, or damaged boots.
6. 6

   Service caliper slide pins
   Remove caliper slide pins from bracket if they were not already removed. Wipe off all old grease completely. Inspect pin surfaces for corrosion, pitting, or scoring. Check rubber boots for tears or damage. Apply fresh synthetic brake caliper grease liberally to slide pins. Reinstall pins into bracket, ensuring boots seat properly and pins move smoothly.
7. 7

   Compress caliper piston
   Before installing new thicker pads, the caliper piston must be compressed fully into its bore. Use a brake caliper piston compression tool or large C-clamp, positioning it against the piston and back of caliper housing. Slowly and steadily compress the piston fully into the caliper bore. Monitor brake fluid reservoir as piston compression will raise fluid level. Remove excess fluid with turkey baster if necessary to prevent overflow. For electronic parking brake calipers, ensure service mode was properly activated in preparation or piston may not retract.
8. 8

   Install new brake hardware
   Install new anti-rattle clips, pad retaining clips, and shims from the hardware kit onto the caliper bracket in the exact positions as the old hardware. Ensure all clips are fully seated and secure. Apply a thin film of brake caliper grease to pad slide contact points on bracket where pads will contact metal (do not get grease on friction material or rotor).
9. 9

   Install new brake pads
   Install new brake pads into caliper bracket, ensuring proper orientation. The pad with wear indicator (if equipped) typically goes on the inboard position. Ensure pads are fully seated in bracket and hardware clips engage properly. Verify pads slide smoothly in bracket without binding. Check that friction material faces the rotor surface.
10. 10

    Reinstall caliper
    Remove caliper from support hook. Position caliper carefully over new brake pads and rotor, ensuring it aligns with mounting holes in bracket. Guide caliper slide pins or mounting bolts through their respective holes. Thread caliper mounting bolts by hand first to ensure proper threading. Torque caliper bolts to manufacturer specification using torque wrench (typically 80-110 ft-lbs, but verify in Rivian service documentation as no torque specs are provided in database). If torque specification cannot be verified, this step requires professional service.
11. 11

    Verify caliper installation
    Verify caliper is securely mounted and both bolts are properly torqued. Check that brake hose has no kinks, twists, or excessive tension. Attempt to move caliper to confirm solid mounting. Visually verify pads are properly positioned on both sides of rotor and no hardware has fallen out of place.
12. 12

    Repeat for opposite side
    Repeat steps 1 through 11 for the opposite front brake assembly. It is critical that both front brakes are serviced identically to ensure balanced braking performance.
13. 13

    Reinstall wheels and lower vehicle
    Reinstall front wheels onto hubs, ensuring wheels seat fully against hub surfaces. Thread lug nuts by hand first. Tighten lug nuts in star pattern to snug (not final torque) while vehicle is still on jack stands. Carefully raise vehicle slightly with jack to remove jack stands. Lower vehicle completely to ground. Torque lug nuts to Rivian specification in star pattern (typically 130-140 ft-lbs for commercial vans, verify in owner's manual).
14. 14

    Restore brake system pressure
    Before moving vehicle, sit in driver's seat and pump brake pedal slowly and steadily 15-20 times until pedal feels firm and reaches normal height. Pedal should become progressively firmer with each pump as pistons extend to contact new pads. First few pedal strokes will feel soft or go to floor - this is normal. Do not start or move vehicle until firm pedal is achieved. If pedal does not firm up after 20 pumps, bleed brake system.
15. 15

    Exit brake service mode and perform relearn
    Using Rivian diagnostic tool, exit brake service mode and perform the electronic brake system relearn procedure per manufacturer instructions. This allows the vehicle's brake control system to recalibrate for new pad thickness and blending of regenerative and friction braking. Clear any brake system fault codes that may have been set during service. Verify no warning lights remain illuminated on dash.

Reassembly

1. Ensure all caliper bolts are torqued to specification
2. Verify brake hoses have no kinks or damage
3. Check brake fluid level and top off to MAX line with DOT 4 fluid if needed
4. Ensure reservoir cap is securely reinstalled
5. Double-check all wheel lug nuts are torqued properly in star pattern

Verification

• Start vehicle and verify no brake warning lights or fault messages appear on instrument cluster
• Check brake pedal feel - should be firm with normal travel, not soft or spongy
• Perform several low-speed brake applications in a safe area to verify proper braking function and seat pads
• Listen for any unusual noises during brake application (squealing, grinding, clicking)
• Test that regenerative braking still functions properly at low speeds
• Perform 10-15 moderate stops from 30-40 mph to properly bed in new brake pads and transfer pad material to rotors
• Avoid heavy braking for first 200 miles to allow proper pad break-in
• Re-check wheel lug nut torque after 50-100 miles of driving
• Monitor brake pedal feel over next several days - any change to soft or low pedal requires immediate inspection
• Verify equal braking performance side-to-side with no pulling during stops

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