Brake Caliper - Front

This procedure covers the removal and installation of the front brake caliper on a 2024 Rivian EDV 500, including proper bleeding and torque specifications for this electric delivery vehicle.

Warnings

Tools required

Parts

• Front brake caliper assembly × 1 — Use OEM Rivian specification
• Copper crush washers for banjo bolt × 2 — Use OEM specification - always replace
• Brake pad retaining clips (if not included with caliper) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Open hood and locate brake fluid reservoir - remove approximately 1/3 of fluid with turkey baster to prevent overflow when compressing caliper piston
4. Access vehicle settings through touchscreen and enable Service Mode to disable regenerative braking if available, or disconnect 12V battery
5. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
6. Raise front of vehicle with floor jack at designated lift points and secure with appropriately rated jack stands
7. Remove front wheel completely
8. Clean brake caliper area with brake cleaner to prevent contamination

Procedure

1. 1

   Remove brake line from caliper
   Place catch pan under caliper area. Using a 14mm flare nut wrench, carefully loosen and remove the brake line banjo bolt connecting the brake hose to the caliper. Be prepared for brake fluid to drain. Cap or plug the brake line immediately with a rubber cap or clean shop towel to prevent fluid loss and contamination. Remove and discard both copper crush washers - these MUST be replaced with new ones during installation.
   ⚠️Brake fluid will drain when disconnecting line. Ensure catch pan is positioned correctly and do not allow fluid to contact painted surfaces or electric components.
2. 2

   Remove caliper mounting bolts
   Locate the two caliper bracket bolts (slide pins) securing the caliper to the bracket. These are typically on the rear of the caliper assembly. Using an 18mm socket or wrench, remove both caliper bracket bolts. Note the location and orientation of any shims or anti-rattle clips for reinstallation.
3. 3

   Remove caliper assembly
   Carefully lift the caliper off the brake rotor and bracket. If caliper is stuck, gently work it free - do not pry against the rotor surface. Remove the brake pads from the caliper or bracket and inspect for unusual wear patterns which may indicate other suspension or brake issues. Set old caliper aside on a clean surface.
4. 4

   Inspect mounting bracket and rotor
   With caliper removed, inspect the caliper mounting bracket for damage, excessive corrosion, or wear. Check that slide pin boots are intact. Inspect the brake rotor for excessive wear, scoring, or warping - measure thickness if necessary. Clean the bracket mounting surfaces and slide pin contact areas with brake cleaner. This is an opportunity to service the rotor if needed.
5. 5

   Prepare new caliper for installation
   Unbox the new caliper and verify it matches the old unit exactly. If caliper piston is not already retracted, use caliper piston compression tool to fully compress the piston into the caliper bore. Ensure the piston dust boot is properly seated and not damaged. Remove any protective caps or plugs from the brake line port.
6. 6

   Install new brake pads and caliper
   Install new or existing brake pads into the caliper bracket with any anti-rattle clips or shims in their correct positions. Apply a thin layer of high-temperature brake grease to pad backing plates (not friction surface) if specified. Carefully position the new caliper over the brake rotor and align with mounting holes. Ensure brake pads are correctly seated on both sides of the rotor.
7. 7

   Install caliper mounting bolts
   Apply medium-strength thread locker to the threads of both caliper bracket bolts as specified by manufacturer. Insert both bolts and hand-tighten. Using a torque wrench and 18mm socket, torque both caliper bracket bolts to 120 Nm (88 lb-ft) in a cross pattern. This is a CRITICAL torque specification - verify your torque wrench is calibrated and the bolts are fully torqued.
   ⚠️Caliper bracket bolts must be torqued to exact specification. Under-torquing can cause caliper detachment and complete brake failure. Over-torquing can strip threads or break bolts.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
8. 8

   Connect brake line to caliper
   Remove any caps or plugs from the brake line. Position NEW copper crush washers (one on each side of the banjo fitting) onto the banjo bolt. Insert the banjo fitting into the caliper port and thread the banjo bolt by hand. Using a 14mm flare nut wrench and torque wrench, tighten the banjo bolt to exactly 25 Nm (18 lb-ft). Do not over-tighten as this can damage the fitting or caliper port.
   ⚠️NEW copper crush washers are mandatory - never reuse old washers. Failure to use new washers will cause brake fluid leaks and potential brake failure.
   Torque spec

   Brake Line Banjo Bolt25 Nm (18 lb-ft)
9. 9

   Bleed brake caliper
   Attach a clear hose to the bleeder screw and submerge the other end in a container with fresh DOT 4 brake fluid. Have an assistant pump the brake pedal 3-5 times and hold pressure, or use a pressure bleeder. Open the bleeder screw 1/4 turn using an 8mm wrench. Allow fluid and air to escape until only clean fluid with no air bubbles flows, then close bleeder screw. Do not allow pedal to go to floor if assistant is pumping. Repeat process until no air bubbles appear. Tighten bleeder screw to 10 Nm (7 lb-ft).
   ⚠Do not overtighten bleeder screw - it is brass and easily damaged. Stripped bleeder screws require caliper replacement.
   ⚠Monitor brake fluid reservoir level constantly during bleeding. Never allow reservoir to run empty or air will enter the system requiring complete system bleeding.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
10. 10

    Reinstall wheel and lower vehicle
    Clean wheel mounting surface on hub. Position wheel onto hub and hand-thread all lug nuts. Lower vehicle until tire just contacts ground. Torque wheel lug nuts to manufacturer specification (typically 160-180 Nm) in a star pattern. Fully lower vehicle and remove jack stands. Double-check all lug nuts are properly torqued.
11. 11

    Fill brake fluid reservoir
    Open brake fluid reservoir cap and fill to MAX line with fresh DOT 4 brake fluid. Ensure cap is tightly sealed. Check reservoir level is between MIN and MAX marks. Wipe any spilled fluid immediately.
12. 12

    Pump brake pedal and verify operation
    With vehicle still stationary and in Park, pump brake pedal slowly 10-15 times until pedal feels firm and reaches normal height. Pedal should not sink to floor under steady pressure. If pedal feels soft or spongy, repeat bleeding procedure. Check all connections for leaks, including banjo bolt and bleeder screw.

Reassembly

1. If Service Mode was enabled, disable it through vehicle touchscreen settings
2. If 12V battery was disconnected, reconnect and allow vehicle systems to initialize
3. Check brake fluid level one final time and top off if necessary with DOT 4 fluid
4. Clean any brake fluid residue from caliper, brake line connections, and surrounding areas with water
5. Verify no tools or parts are left in wheel well or under vehicle

Verification

• With engine off, pump brake pedal 10-15 times - pedal should be firm and not sink to floor under steady pressure
• Start vehicle and verify brake warning light is not illuminated on dash
• Check for any brake fluid leaks around banjo bolt connection and bleeder screw while assistant applies firm pressure to brake pedal
• Perform a low-speed brake test (5-10 mph) in a safe area - braking should be smooth with no pulling to either side
• Perform a moderate-speed brake test (20-30 mph) in a safe area - verify proper stopping power and pedal feel
• Check brake fluid reservoir level after test drive - top off if necessary
• Listen for any unusual noises during braking (grinding, squealing, rubbing)
• If vehicle has brake pad wear sensors, verify no warning lights are present
• Re-torque wheel lug nuts after 50-100 miles of driving

Related trouble codes on this vehicle

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