Brake Pads and Rotors - Front

This procedure covers the removal and replacement of front brake pads and rotors on the 2024 Rivian EDV 500 electric delivery van, including proper bedding-in procedures for optimal braking performance.

Warnings

Tools required

Parts

• Front brake pad set × 1 — Use OEM Rivian specification for EDV 500
• Front brake rotors (pair) × 2 — Use OEM Rivian specification for EDV 500
• Brake hardware kit (clips and shims) × 1 — Usually included with pad set
• Brake pad wear sensor (if equipped) × 2 — Check existing sensor condition

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake (rear wheels only on this AWD vehicle)
2. Place wheel chocks behind rear wheels
3. Turn vehicle OFF and ensure it is fully powered down (verify instrument cluster is dark)
4. If equipped with electronic parking brake or brake service mode, consult Rivian documentation for proper system preparation
5. Open hood and locate brake fluid reservoir. Check fluid level and mark current level
6. Using turkey baster or fluid pump, remove approximately 2 oz of brake fluid from reservoir to prevent overflow when compressing caliper pistons
7. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
8. Lift front of vehicle with floor jack at designated jacking points per owner's manual
9. Secure vehicle on jack stands rated for at least 5 tons at proper support points
10. Remove front wheels completely and set aside
11. Inspect brake system for fluid leaks, damaged lines, or other obvious issues before proceeding

Procedure

1. 1

   Remove caliper from mounting bracket
   Locate the two caliper slide pin bolts (typically on the rear of the caliper). These are usually 14mm or 15mm bolts. Remove both bolts while supporting the caliper with your other hand. Once bolts are removed, carefully pivot the caliper upward and off the rotor. Do NOT let the caliper hang by the brake hose. Support it using a wire hanger or bungee cord attached to the suspension or frame.
2. 2

   Remove old brake pads
   With the caliper removed, remove the brake pads from the caliper bracket. Note the position of any anti-rattle clips, shims, or wear sensors. Take photos for reference during reassembly. Remove and discard old brake pad hardware clips from the caliper bracket.
3. 3

   Remove caliper mounting bracket
   Locate the two caliper bracket mounting bolts (typically larger than slide pin bolts, often 17mm-19mm). These bolts secure the bracket to the steering knuckle and are torqued to high values. Remove both bolts and remove the caliper bracket completely. Set aside with the caliper.
4. 4

   Remove brake rotor
   If present, remove any Torx or Phillips screws securing the rotor to the hub (these are typically T30 or T40 Torx). The rotor may be stuck due to corrosion. If stuck, use a rubber mallet to tap the rotor from behind to break it free. Alternatively, thread bolts into the threaded holes in the rotor face (if equipped) to press it off the hub. Remove the old rotor completely.
5. 5

   Clean hub and prepare mounting surface
   Use a wire brush to thoroughly clean the wheel hub face where the rotor mounts. Remove all rust, scale, and debris. Clean the hub surface with brake cleaner and allow to dry. Any debris or high spots here will cause rotor runout and brake pulsation. The mating surface must be completely clean and flat.
6. 6

   Install new brake rotor
   Remove the protective coating from the new rotor using brake cleaner (both sides). Wipe dry with clean, lint-free cloth. Slide the new rotor onto the hub, ensuring it sits completely flush. If equipped with rotor retention screws, install them and tighten snugly (do not overtighten as they are only for assembly retention). Apply a small amount of thread-locking compound if desired.
7. 7

   Compress caliper piston
   Before installing the caliper bracket, the caliper piston(s) must be compressed to accommodate the new, thicker brake pads. Place a C-clamp or brake caliper piston tool over the caliper body and piston. Slowly compress the piston(s) back into the caliper bore until fully retracted. Watch the brake fluid reservoir during this process to ensure it does not overflow. If it approaches the MAX line, remove more fluid.
8. 8

   Reinstall caliper mounting bracket
   Position the caliper mounting bracket over the rotor and align with the mounting holes on the steering knuckle. Install both bracket mounting bolts. Without manufacturer torque specifications available, tighten these bolts firmly to approximately 70-90 ft-lbs (consult Rivian documentation for exact values). These bolts are critical to brake safety and must be properly torqued.
9. 9

   Install new brake pad hardware and pads
   Install new brake pad hardware clips onto the caliper bracket, ensuring they snap securely into place. Apply a thin layer of high-temperature brake lubricant to the pad backing plate contact points (where pads slide in bracket) and to the caliper slide pins. Install the new inner and outer brake pads into the bracket, ensuring they are properly seated in the hardware clips. If equipped with wear sensors, connect the sensor wiring and route properly to avoid contact with rotating components.
10. 10

    Reinstall brake caliper
    Carefully position the caliper over the new brake pads and rotor. Align the caliper with the slide pin holes. Install both caliper slide pin bolts and tighten. Without manufacturer specifications, tighten to approximately 25-35 ft-lbs (consult Rivian documentation for exact values). Ensure the caliper moves freely on the slide pins and is not binding.
11. 11

    Repeat for opposite side
    Perform steps 1 through 10 on the opposite front wheel to replace the other front brake pads and rotor. Ensure both sides are completed with equal care and attention to detail.
12. 12

    Restore brake pedal pressure
    Before installing wheels, sit in the driver's seat and slowly pump the brake pedal 10-15 times until it becomes firm. The first several pumps will feel soft as the caliper pistons extend to contact the new pads. The pedal should become firm and hold steady pressure. If the pedal goes to the floor, there is air in the system or a problem with the installation. Do NOT drive the vehicle.
13. 13

    Check brake fluid level
    Check the brake fluid reservoir and top off with fresh DOT 4 brake fluid to the MAX line. Do not overfill. Ensure the reservoir cap is securely reinstalled. Inspect around all brake connections for any signs of fluid leakage.
14. 14

    Reinstall wheels and lower vehicle
    Reinstall both front wheels, threading lug nuts by hand initially to avoid cross-threading. Tighten lug nuts in a star pattern to snug while vehicle is still on jack stands. Lower vehicle to the ground. With vehicle weight on wheels, torque lug nuts to manufacturer specification (typically 140-150 ft-lbs for this class of vehicle, but verify in owner's manual) using a star pattern.
15. 15

    Perform brake bedding procedure
    New pads and rotors require a bedding process for optimal performance. Find a safe, open road with minimal traffic. From 40-45 mph, perform 6-8 moderate stops (approximately 50% brake pressure) down to 15 mph without coming to a complete stop. Allow 30 seconds between each stop for cooling. Then perform 2-3 harder stops from 50-55 mph down to 20 mph (approximately 75% brake pressure). Do NOT come to a complete stop immediately after hard braking as this can cause pad material transfer to the rotor. Allow brakes to cool for 10-15 minutes before normal use. Note that regenerative braking will affect this process - consult Rivian documentation for EDV-specific bedding recommendations.

Reassembly

1. Torque all fasteners to manufacturer specifications when available
2. Ensure all brake pad wear sensor connectors are properly connected and secured
3. Verify brake fluid level is between MIN and MAX lines
4. Ensure no tools or parts have been left in wheel wells or under vehicle
5. Check that all wheels are properly torqued using a star pattern

Verification

• Before moving vehicle, pump brake pedal 10-15 times and verify firm, consistent pedal feel with no sinking
• Start vehicle and verify no brake warning lights are illuminated on instrument cluster
• Check brake fluid reservoir one final time for proper level and no leaks around cap
• Perform a low-speed test drive in a safe area, testing brakes at 5-10 mph to verify proper operation
• Inspect all work areas for fluid leaks after test drive
• Listen for any unusual noises during brake application (light squealing during break-in is normal, but grinding or loud noise is not)
• Verify regenerative braking system is functioning normally alongside friction brakes
• After 50-100 miles, re-check wheel lug nut torque and brake fluid level
• If equipped with tire pressure monitoring system (TPMS), verify all sensors are reading correctly after wheel reinstallation

Related trouble codes on this vehicle

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