Brake Rotor - Rear Single

This procedure covers the removal and replacement of a single rear brake rotor on a 2024 Rivian EDV 500, including caliper and carrier removal.

Warnings

Tools required

Parts

• Rear brake rotor × 1 — Use OEM specification for Rivian EDV 500
• Rotor set screws (if equipped) × 2 — M6 x 1.0 or per OEM specification

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on a level, hard surface and place transmission in Park
2. Apply parking brake and place wheel chocks in front of the front wheels
3. Power down the vehicle completely using the touchscreen (Safety & Security > Power Off)
4. Wait at least 5 minutes after power-off for high-voltage systems to discharge
5. Loosen the rear wheel lug nuts 1/4 turn while the wheel is still on the ground
6. Lift the rear of the vehicle using a floor jack at the designated rear jacking point
7. Place jack stands under the frame rails at manufacturer-designated support points
8. Lower the vehicle onto the jack stands and verify stability
9. Remove the wheel lug nuts completely and remove the wheel
10. Inspect the brake system for any damage, excessive wear, or fluid leaks

Procedure

1. 1

   Inspect brake fluid level
   Open the hood and locate the brake fluid reservoir. Check the current fluid level and note the position. The fluid level will rise when the caliper piston is compressed. If the reservoir is at the MAX line, remove some fluid using a turkey baster or fluid pump to prevent overflow.
   ⚠Brake fluid absorbs moisture and becomes contaminated. Use only fresh DOT 4 brake fluid from a sealed container.
2. 2

   Remove caliper bolts
   Locate the two caliper mounting bolts on the rear of the caliper. These are typically 14mm or 15mm bolts. Using a socket and breaker bar, loosen and remove both caliper mounting bolts. Keep track of these bolts as they will be reused.
   ℹ️On some Rivian models, the caliper bolts may have thread-locking compound applied from the factory.
3. 3

   Remove and secure brake caliper
   Carefully lift the brake caliper off the rotor and brake pads. Do not let the caliper hang by the brake hose. Use a caliper hanger, bungee cord, or heavy wire to securely hang the caliper from the suspension or frame. Ensure there is no tension on the brake hose.
   ⚠Allowing the caliper to hang by the brake hose can cause internal damage and brake failure.
4. 4

   Remove brake pads
   Remove the brake pads from the caliper bracket. Note the orientation and position of any anti-rattle clips or shims. Inspect the pads for wear. If the pads are worn below 3mm thickness, they should be replaced during reassembly.
5. 5

   Remove caliper bracket
   Locate the two caliper bracket mounting bolts that secure the bracket to the axle hub. These bolts are typically larger (17mm-19mm) than the caliper bolts. Using a socket and breaker bar, remove both bracket bolts. Remove the caliper bracket assembly.
   ℹ️Caliper bracket bolts are typically torqued to a higher specification than caliper bolts. These will be tight.
6. 6

   Remove rotor retaining screws
   If equipped, remove the small Phillips or hex-head retaining screws that secure the rotor to the hub. These screws may be corroded or have thread-locking compound. Use penetrating oil if needed. If the screws are severely corroded and strip, they can be drilled out as they are not structurally necessary.
7. 7

   Remove brake rotor
   Attempt to pull the rotor straight off the hub. If the rotor is stuck due to corrosion, use a rubber mallet to tap around the outer edge of the rotor hat (center section). Do not strike the rotor friction surface. If still stuck, thread appropriately sized bolts into the threaded removal holes (if present) to push the rotor off the hub.
   ⚠Never strike the rotor friction surface with a hammer as this can cause cracks or warping.
8. 8

   Clean hub mounting surface
   Using a wire brush and brake parts cleaner, thoroughly clean the hub mounting surface where the rotor seats. Remove all rust, corrosion, and debris. The surface should be smooth and flat to ensure proper rotor seating and prevent runout.
9. 9

   Install new brake rotor
   Apply a thin layer of anti-seize compound to the hub mounting surface (avoid getting any on the rotor friction surfaces). Position the new rotor onto the hub, ensuring it seats fully and flush against the hub face. If equipped, install new rotor retaining screws and tighten securely by hand.
   ⚠Remove any protective coating from new rotors using brake parts cleaner before installation. Handle rotors with clean gloves to avoid contaminating the friction surface with oil.
10. 10

    Reinstall caliper bracket
    Position the caliper bracket over the rotor and align the mounting bolt holes with the hub. Install both caliper bracket bolts and tighten in a crisscross pattern. Without manufacturer torque specifications, these bolts should be very tight (typically 80-120 ft-lb on similar vehicles). Recommend verification with Rivian service documentation.
    ⚠️Improperly torqued caliper bracket bolts can result in brake failure. Consult Rivian service center for proper torque specification.
11. 11

    Compress brake caliper piston
    Before reinstalling the caliper, the piston must be compressed to accommodate the new rotor and pads. Use a brake piston compression tool or large C-clamp to slowly compress the piston fully into the caliper bore. Monitor the brake fluid reservoir and remove fluid if it begins to overflow.
    ℹ️For rear calipers with integrated parking brake, a special tool may be required to rotate and compress the piston. Verify caliper type before proceeding.
12. 12

    Reinstall brake pads and caliper
    Install the brake pads into the caliper bracket in their correct orientation with any clips or shims. Position the caliper over the pads and rotor. Install the caliper mounting bolts and tighten. Without manufacturer specifications, tighten to approximately 30-35 ft-lb or as tight as can be achieved with a standard ratchet (typical for similar vehicles).
    ⚠️Improperly torqued caliper bolts can result in brake failure. Consult Rivian service center for proper torque specification.
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the wheel onto the hub, ensuring it seats properly. Install all lug nuts and tighten by hand. Raise the vehicle slightly with the floor jack and remove the jack stands. Lower the vehicle until the tire just contacts the ground. Torque the lug nuts to specification in a star pattern. Fully lower the vehicle and remove the jack.
    ⚠️Improperly torqued wheel lug nuts can cause wheel separation. Consult owner's manual for correct torque specification (typically 130-150 ft-lb for commercial vehicles).
14. 14

    Restore brake pedal
    Before driving, pump the brake pedal several times until it becomes firm. This restores proper brake caliper piston position. Check the brake fluid level in the reservoir and top off with fresh DOT 4 brake fluid if needed to bring it to the MAX line.
    ⚠️Do not attempt to drive the vehicle until the brake pedal feels firm and normal. A soft pedal indicates air in the system or improper installation.

Reassembly

1. Reassembly is detailed in the steps above, following reverse order of disassembly
2. Ensure all fasteners are properly torqued to manufacturer specifications
3. Apply anti-seize compound to appropriate surfaces to prevent future corrosion
4. Top off brake fluid reservoir to MAX line with fresh DOT 4 brake fluid
5. Dispose of old rotor and any used brake fluid according to local environmental regulations

Verification

• Pump brake pedal multiple times to verify firm pedal feel before driving
• Check brake fluid level and inspect for any leaks around caliper and brake lines
• Perform a low-speed brake test in a safe area to verify proper brake operation
• Listen for any abnormal noises during brake application (squealing, grinding, or rattling)
• Verify that the vehicle does not pull to one side during braking
• After first 50-100 miles, re-torque wheel lug nuts to specification
• Bedding-in procedure: Perform 20-30 moderate stops from 40-45 mph to properly bed the new rotor and pads
• Schedule follow-up inspection if you notice any brake pulsation, noise, or reduced stopping power
• If brake warning light illuminates or pedal feel is abnormal, do not drive vehicle and consult professional service immediately

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