Brake Caliper - Rear

This procedure covers the removal and replacement of the rear brake caliper on a 2024 Rivian EDV 500, including bleeding the hydraulic brake system.

Warnings

Tools required

Parts

• Rear brake caliper assembly × 1 — Use OEM Rivian specification
• Copper crush washers for banjo bolt × 2 — Use OEM specification
• Threadlocker (medium strength) × 1 — Loctite 243 or equivalent
• Brake pads (if not included with caliper) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks in front of front wheels
3. Power down the vehicle completely and wait 5 minutes for high voltage systems to discharge
4. Connect Rivian diagnostic tool and navigate to Service Functions > Brake Service Mode
5. Activate rear caliper service mode to retract electronic parking brake pistons
6. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
7. Raise rear of vehicle with floor jack and support securely on jack stands at designated lift points
8. Remove rear wheel and set aside
9. Inspect brake system for any signs of damage or unusual wear before proceeding

Procedure

1. 1

   Prepare brake hydraulic system
   Open the brake fluid reservoir cap in the front compartment to allow fluid to return during caliper removal. Place absorbent cloth around reservoir to catch any overflow. Have a drain pan ready beneath the caliper work area to catch brake fluid.
2. 2

   Remove brake line from caliper
   Using a 10mm flare nut wrench, carefully loosen the brake line banjo bolt connecting the brake hose to the caliper. Once loosened, remove the bolt completely and separate the brake line from the caliper. Immediately plug the brake line opening with a rubber cap or clean shop towel to prevent fluid loss and contamination. Discard the old copper crush washers - these must not be reused.
   ⚠Brake fluid will drain from the line. Position drain pan to catch fluid. Do not allow fluid to contact painted surfaces or the ground.
3. 3

   Support brake caliper
   Before removing mounting bolts, prepare to support the caliper weight. If the brake line was not completely removed, use mechanics wire to hang the caliper from the suspension to prevent strain on the brake hose. Since line is removed in this procedure, have a clean work surface ready to place the old caliper.
4. 4

   Remove caliper bracket bolts
   Locate the two caliper bracket bolts securing the caliper assembly to the rear knuckle. Using an 18mm socket and breaker bar if needed, remove both caliper bracket bolts. These bolts are torqued to high specification and may require significant force to loosen. Remove the caliper assembly from the rotor and set aside on a clean surface.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
5. 5

   Inspect mounting surfaces and brake components
   With caliper removed, inspect the rotor surface for excessive wear, scoring, or hot spots. Check the caliper mounting bracket on the knuckle for damage or corrosion. Clean mounting surfaces with brake cleaner if needed. Inspect brake pads if reusing them. This is an ideal time to measure rotor thickness and inspect other brake components.
6. 6

   Prepare new caliper for installation
   Remove the new caliper from packaging and verify it matches the old unit. Check that bleeder screw is present and closed. If brake pads are not pre-installed, install them now according to manufacturer instructions. Ensure caliper piston is fully retracted - if not, carefully compress it using a C-clamp or brake piston tool. Remove any protective caps from hydraulic ports.
7. 7

   Apply threadlocker to bracket bolts
   Clean the threads of both caliper bracket bolts with brake cleaner and allow to dry. Apply medium-strength threadlocker (Loctite 243 or equivalent) to the bolt threads as specified in torque specifications. This prevents loosening from vibration and thermal cycling.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
8. 8

   Install new caliper assembly
   Position the new caliper assembly over the brake rotor and align with the mounting holes on the rear knuckle. Insert both caliper bracket bolts and hand-thread them several turns to ensure proper thread engagement. Tighten both bolts in an alternating pattern to 100.0 Nm (74 lb-ft) using a torque wrench.
   ⚠️Proper torque is CRITICAL for safe brake operation. Under-torqued bolts can allow caliper movement and brake failure. Verify torque wrench calibration.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
9. 9

   Connect brake hydraulic line
   Remove the plug or cap from the brake line. Install NEW copper crush washers on both sides of the banjo fitting (one on each side of the connection point). Position the brake line banjo fitting to the caliper port and insert the banjo bolt. Hand-thread the bolt, then torque to 25.0 Nm (18 lb-ft) using a torque wrench. Verify the brake line is not twisted or kinked.
   ⚠️CRITICAL: New copper crush washers are mandatory. Reused washers will leak brake fluid causing brake failure. Verify washers are in place before tightening.
   Torque spec

   Brake Line Banjo Bolt25 Nm (18 lb-ft)
10. 10

    Bleed rear brake caliper
    Attach clear bleeding tubing to the caliper bleeder screw and place the other end in a container partially filled with clean DOT 4 brake fluid. Loosen the bleeder screw by 1/4 turn using an 8mm hex key. Have an assistant slowly press the brake pedal to the floor, then hold. Tighten the bleeder screw to 10.0 Nm (7 lb-ft), then have assistant release the pedal. Repeat this process until no air bubbles appear in the tubing and only clean fluid flows. Maintain brake fluid reservoir level throughout bleeding process.
    ⚠Do not allow brake fluid reservoir to run empty during bleeding or air will enter the master cylinder requiring additional bleeding.
    ⚠Do not overtighten bleeder screw as this may strip the threads or crack the caliper body.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Reinstall wheel and perform initial checks
    Reinstall the rear wheel and hand-thread all lug nuts. Lower vehicle until tire just contacts ground (to prevent rotation), then torque lug nuts to manufacturer specification in a star pattern. Fully lower vehicle and remove jack stands. Close brake fluid reservoir and verify level is at MAX mark.
12. 12

    Deactivate caliper service mode and perform system test
    Using the Rivian diagnostic tool, exit brake service mode to restore normal electronic parking brake operation. With vehicle still stationary, pump brake pedal several times to verify firm pedal feel. Check all connections for any signs of brake fluid leakage. Start vehicle and verify no brake warning lights are illuminated on instrument cluster.

Reassembly

1. Ensure all brake line connections are tight and leak-free
2. Verify brake fluid reservoir is filled to MAX mark with clean DOT 4 fluid
3. Confirm wheel lug nuts are torqued to specification
4. Verify electronic parking brake system has been properly reactivated via diagnostic tool
5. Clean any spilled brake fluid from surrounding areas immediately with water

Verification

• With vehicle stationary, press brake pedal firmly - it should feel solid and not sink to the floor
• Inspect all brake line connections and bleeder screw for any signs of fluid leakage
• Test electronic parking brake engagement and release function from vehicle controls
• Perform a low-speed test drive (under 10 mph) in a safe area to verify brake response before normal operation
• During test drive, verify no pulling to either side during braking and no unusual noises
• Perform several moderate brake applications from 30 mph to properly bed new caliper/pads
• After 50-100 miles of driving, recheck brake fluid level and inspect caliper area for any leaks
• Re-verify caliper bracket bolt torque after first test drive if possible

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