Brake Rotors - Rear Pair

This procedure covers the removal and replacement of the rear brake rotors on a 2024 Rivian EDV 500 electric delivery van, including proper bedding procedures for the new rotors.

Warnings

Tools required

Parts

• Rear brake rotor × 2 — Use OEM Rivian specification
• Brake rotor set screws (if equipped) × 4 — M6x1.0 set screws

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid surface and engage electronic parking brake
2. Place wheel chocks in front of both front wheels
3. Using the center touchscreen, place the vehicle into Service Mode (Settings > Service > Service Mode). This disables regenerative braking and prevents unexpected motor activation
4. Loosen rear wheel lug nuts while vehicle is still on the ground (do not remove)
5. Consult owner's manual and locate designated rear jacking points on the frame rails
6. Lift rear of vehicle using floor jack at center rear lift point
7. Place jack stands under designated frame rail lift points on both sides
8. Remove rear wheels completely and set aside
9. Verify brake fluid reservoir level is at maximum before beginning work

Procedure

1. 1

   Access brake caliper assembly
   Inspect the rear brake assembly. Locate the brake caliper, which is mounted over the rotor. Identify the two caliper mounting bolts on the rear of the caliper bracket. Spray brake parts cleaner on all brake components and allow to dry. Clean any accumulated road debris from the caliper and rotor area with a wire brush.
2. 2

   Retract brake caliper pistons
   Before removing the caliper, the pistons must be retracted to provide clearance. Open the brake fluid reservoir cap slightly to prevent vacuum lock. Using a C-clamp or brake caliper piston tool, carefully compress the caliper pistons back into their bores by pressing against the back of the inboard brake pad. Monitor the brake fluid reservoir and ensure it does not overflow. On the EDV 500, the rear calipers may have electronic parking brake actuators integrated into the piston assembly - if resistance is encountered, the parking brake may need to be released electronically via scan tool.
   ⚠Do not allow brake fluid to contact painted surfaces. Brake fluid is corrosive and will damage paint. Have clean rags ready to catch any drips.
3. 3

   Remove brake caliper
   Remove the two caliper slide pin bolts or mounting bolts that secure the caliper to the caliper bracket (typically 18mm). Carefully lift the caliper assembly straight up and off the rotor. Do NOT allow the caliper to hang by the brake hose - this will damage the hose. Support the caliper using a brake caliper hanger hooked to the suspension or secure it with mechanic's wire to the suspension component above. Ensure there is no tension on the brake flex hose.
4. 4

   Remove caliper bracket
   Locate the two caliper bracket mounting bolts that secure the bracket to the rear axle hub assembly (typically larger than caliper bolts, often 21mm). These bolts are typically very tight and may require a breaker bar for removal. Remove both bracket mounting bolts completely and remove the caliper bracket assembly from the hub. Set bracket and hardware aside in a clean area.
5. 5

   Remove brake rotor
   With the caliper bracket removed, the rotor should now be free. If the rotor has set screws (small Phillips or hex screws) securing it to the hub face, remove these first. If the rotor is stuck due to corrosion, tap it gently from behind with a rubber mallet while rotating the rotor. Do NOT strike the rotor face or braking surface. If extremely corroded, spray penetrating oil around the hub center and allow to soak before attempting removal again. Remove the old rotor completely.
6. 6

   Clean hub mounting surface
   With the rotor removed, thoroughly clean the hub mounting surface with a wire brush to remove all rust, corrosion, and debris. The hub face must be completely clean and smooth to ensure proper rotor seating. Any debris or high spots will cause rotor runout and brake pulsation. Clean the wheel studs and surrounding area as well. Spray the hub face with brake parts cleaner and wipe clean with a lint-free cloth.
7. 7

   Prepare and install new rotor
   Remove the new rotor from packaging. New rotors are typically coated with a protective oil or wax to prevent corrosion during shipping. Thoroughly clean both sides of the new rotor with brake parts cleaner to remove all protective coating - this is critical for proper brake function. Wipe dry with clean, lint-free cloths. Position the new rotor onto the hub, aligning any set screw holes. If equipped with rotor set screws, install them finger-tight at this stage to hold the rotor in position (they will be secured with thread-locking compound).
8. 8

   Install caliper bracket
   Position the caliper bracket back onto the hub assembly, aligning the mounting bolt holes. Install both caliper bracket mounting bolts and hand-thread them to ensure proper alignment. Since no torque specifications are available in the database, tighten the bracket bolts to manufacturer specification found in the vehicle service manual or using equivalent commercial vehicle specifications (typically 125-150 ft-lbs for rear caliper brackets on heavy vehicles). Ensure the bracket is fully seated and secure.
9. 9

   Secure rotor set screws
   If the rotor has set screws, apply a small amount of medium-strength thread-locking compound to each screw and tighten them securely (typically 7-9 ft-lbs, but consult service manual). These screws prevent rotor rotation during maintenance but are not structural for braking.
10. 10

    Reinstall brake caliper
    Inspect brake pads for wear. If rotors are being replaced, brake pads should also be inspected and typically replaced. Remove the caliper from its hanger or support wire. Position the caliper over the new rotor and bracket, ensuring the brake pads properly align on both sides of the rotor. Install the caliper mounting bolts or slide pins and tighten to manufacturer specification (typically 35-45 ft-lbs for slide pin bolts, consult service manual). Verify the caliper moves freely if it uses a sliding mechanism.
11. 11

    Repeat for opposite side
    Perform steps 1 through 10 on the opposite rear brake rotor. Always replace rotors in pairs to maintain balanced braking performance.
12. 12

    Check brake fluid level
    After both calipers have been reinstalled with pistons compressed, check the brake fluid reservoir. The level should be between the MIN and MAX marks. Add DOT 4 brake fluid as necessary to bring to the MAX line. Securely reinstall the reservoir cap.
13. 13

    Reinstall wheels and lower vehicle
    Reinstall both rear wheels, threading lug nuts by hand initially to ensure proper seating. Tighten lug nuts in a star pattern to snug, but do not torque yet. Carefully raise the vehicle slightly with the floor jack to remove jack stands. Lower the vehicle completely to the ground. With the vehicle weight on the wheels, torque the lug nuts to specification in a star pattern (consult owner's manual, typically 140-150 ft-lbs for the EDV 500).
14. 14

    Perform brake system reset and calibration
    Connect a Rivian-compatible diagnostic scan tool to the vehicle's OBD-II port. Access the brake system module and perform a brake system reset/relearn procedure. This recalibrates the regenerative braking coordination with the friction brakes. Exit Service Mode through the touchscreen interface. Pump the brake pedal several times with the vehicle off until the pedal feels firm and consistent.

Reassembly

1. Ensure all caliper mounting hardware is torqued to specification
2. Verify brake fluid level is at MAX line and reservoir cap is secure
3. Confirm wheel lug nuts are torqued in star pattern to specification
4. Double-check that Service Mode has been exited on the touchscreen
5. Verify no tools or parts have been left in the wheel well area

Verification

• Before driving, pump the brake pedal multiple times until firm pedal is achieved. The pedal should not sink to the floor.
• Start the vehicle and verify no brake warning lights are illuminated on the instrument cluster
• Perform a low-speed brake test in a safe area (5-10 mph) to verify brakes engage properly without pulling to one side
• CRITICAL: Perform proper brake bedding procedure - Make 6-10 moderate stops from 40-45 mph down to 15 mph with gradual braking, allowing 30-60 seconds of light driving between stops to cool the brakes. Avoid hard braking for the first 200-300 miles.
• After bedding and initial test drive, recheck brake fluid level and inspect for any fluid leaks around caliper connections
• Listen for any unusual noises during braking (squealing, grinding, or rubbing)
• Monitor brake pedal feel over the next several days - it should remain firm and consistent
• If brake pedal feels soft, pulsates, or if vehicle pulls to one side during braking, stop driving immediately and have the system inspected by a qualified technician

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