Brake Caliper Rebuild - Rear

Complete disassembly, inspection, cleaning, and rebuild of rear brake calipers on the 2024 Rivian EDV 500, including replacement of all seals, pistons, and hardware.

Warnings

Tools required

Parts

• Rear brake caliper rebuild kit (seals, boots, pistons) × 2 — Use OEM Rivian specification
• Brake caliper guide pin boots and hardware kit × 2 — Use OEM specification
• Copper crush washers for brake line banjo bolts × 4 — Use OEM specification
• Brake pad anti-squeal compound × 1 — High-temp ceramic brake compound
• Silicone brake grease (red rubber grease) × 1 — Brake caliper assembly grease
• Brake cleaner solvent × 2 — Non-chlorinated brake cleaner

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Review the complete procedure before beginning and verify you have all necessary tools and parts
2. Park vehicle on level ground, place transmission in PARK, and apply front wheel chocks
3. Connect Rivian diagnostic tool and access service mode for brake caliper service
4. Using diagnostic tool, retract electronic parking brake actuators fully to service position
5. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes for system power-down
6. Lift vehicle using appropriate lift points specified in Rivian service manual and support on heavy-duty jack stands
7. Remove rear wheels and set aside in clean area
8. Inspect brake system for any signs of uneven wear, damage, or contamination that might indicate additional problems
9. Photograph caliper orientation and brake line routing for reference during reassembly
10. Place absorbent pads and collection containers under work area to catch brake fluid
11. Verify replacement rebuild kits are complete and correct for rear calipers before disassembly

Procedure

1. 1

   Remove rear brake calipers from vehicle
   Place a drain pan under the caliper. Using a line wrench, carefully loosen the brake line banjo bolt at the caliper connection. Allow brake fluid to drain into container. Cap or plug the brake line immediately to prevent contamination. Remove caliper mounting bolts (note: torque specifications not available in database - record original torque or consult Rivian service documentation). Carefully slide caliper off the rotor and bracket. If electronic parking brake cables are present, disconnect the electrical connector after noting orientation. Place caliper on clean workbench protected with clean shop towels.
2. 2

   Disassemble caliper and remove pistons
   Remove brake pads if still attached and set aside. Remove any retaining clips, guide pins, or dust boots from the caliper body. To remove pistons, use compressed air method: Insert a compressed air nozzle (with rubber tip or adapter) into the brake fluid inlet port. Use LOW pressure (20-30 PSI maximum) and gradually apply air while controlling the piston with a shop towel or wood block. NEVER place fingers in front of piston path - pistons can eject with significant force. For multi-piston calipers, remove one piston at a time by placing wooden blocks in empty bores to prevent other pistons from ejecting. Remove all pistons and place on clean surface.
3. 3

   Remove all seals and boots from caliper bores
   Using non-marring plastic or wooden seal picks, carefully remove the piston seals from the grooves in each caliper bore. Work methodically around the seal groove to avoid scratching or gouging the aluminum bore surface. Remove dust boots and any additional O-rings or seals. Inspect the grooves carefully for any debris, corrosion, or damage. Any sharp edges or burrs in seal grooves will cause premature seal failure and must be addressed.
4. 4

   Clean and inspect caliper body
   Thoroughly clean the entire caliper body using brake parts cleaner and non-metallic brushes. Clean all fluid passages, piston bores, and mounting surfaces. Use compressed air to blow out all passages and dry completely. Inspect each piston bore with a bright light looking for ANY pitting, scoring, corrosion, or damage. Measure bore diameter with micrometer at multiple points and compare to specification (consult Rivian service data). If bores show minor staining only (no pitting), they may be acceptable. If light pitting is present, bores may be honed with proper brake caliper hone - but significant pitting requires caliper replacement. Inspect caliper body for cracks, especially around mounting points and fluid ports.
5. 5

   Inspect and measure pistons
   Clean each piston thoroughly with brake cleaner and inspect for scoring, pitting, or corrosion. Even minor surface imperfections on the piston sealing surface will cause seal failure. Measure piston diameter with micrometer and compare to specifications. Check that pistons are not bent or deformed. Most rebuild kits include new pistons - use them unless absolutely certain existing pistons are in perfect condition. Inspect piston coating (typically chrome or phenolic) for any damage. If pistons are reused, they must be absolutely perfect.
6. 6

   Prepare caliper bores for reassembly
   Ensure caliper bores are completely clean and dry. Apply a thin, even coat of fresh DOT 4 brake fluid to each piston bore as assembly lubricant. Verify all seal grooves are clean and undamaged. Check that all fluid passages are clear by blowing compressed air through the caliper body from the bleeder valve to the inlet port.
7. 7

   Install new piston seals
   Remove new piston seals from rebuild kit and lubricate lightly with fresh DOT 4 brake fluid. Using clean fingers (nitrile gloves recommended), carefully install each seal into its groove in the caliper bore. Work the seal gently around the entire groove, ensuring it seats properly without twisting. The seal should sit evenly in the groove with no sections protruding or pinched. Verify each seal is fully seated by running a clean finger around the bore - you should feel a smooth transition with no high spots.
8. 8

   Install pistons and dust boots
   Lubricate new or cleaned pistons with fresh DOT 4 brake fluid. Carefully align each piston with its bore and press in by hand, rotating slightly to start the piston past the seal. The piston should slide in with moderate, even resistance. If using special piston installation tool from rebuild kit, follow kit instructions. Press piston in until it is approximately flush with or slightly recessed into the caliper body. Install new dust boots according to rebuild kit instructions, ensuring they seat properly in both the piston groove and caliper body groove. Verify boots are not torn, twisted, or improperly seated.
9. 9

   Rebuild caliper guide pin assemblies
   Remove guide pins/bolts from caliper bracket. Clean pins thoroughly and inspect for wear, scoring, or corrosion. Clean guide pin bores in caliper bracket. Install new guide pin boots from hardware kit. Apply silicone brake grease (red rubber grease) to guide pins according to service manual specifications - typically a thin coat on the sliding surfaces only. Install boots onto pins and insert pins into bracket, ensuring smooth sliding motion. Guide pins must slide freely without binding or excessive play.
10. 10

    Reassemble and install calipers on vehicle
    Clean caliper mounting brackets and apply appropriate anti-seize or brake grease to mounting surfaces where specified. Install rebuilt calipers onto mounting brackets and rotor assembly. Install caliper mounting bolts and tighten following proper sequence (consult Rivian documentation for specific torque values as none are available in database). Reconnect electronic parking brake connectors if equipped, ensuring proper orientation and secure connection. Install NEW copper crush washers on brake line banjo bolts. Connect brake lines to calipers and tighten banjo bolts to proper specification (consult Rivian service data).
11. 11

    Bleed brake system completely
    Fill brake fluid reservoir with fresh DOT 4 brake fluid from sealed container. Beginning with the rear brake farthest from the master cylinder, attach bleeder hose to bleeder valve. Using pressure bleeder or two-person manual bleeding method, open bleeder valve and allow fluid to flow until completely free of air bubbles. Close bleeder valve before releasing brake pedal (if manual bleeding). Repeat process for all four wheels in proper bleeding sequence (typically RR, LR, RF, LF for this vehicle configuration). Continue bleeding until fluid runs clear with absolutely no air bubbles at any wheel. Monitor reservoir level constantly - never allow reservoir to run empty during bleeding process. Electronic parking brake system may require separate bleeding procedure using diagnostic tool.
12. 12

    Test parking brake function and perform system relearn
    Using Rivian diagnostic tool, perform electronic parking brake function test and calibration procedure. Command parking brake to apply and release multiple times, verifying smooth operation without unusual noise or binding. Check for diagnostic trouble codes related to brake system. Perform brake pressure sensor calibration if required by service procedures. Verify parking brake holds vehicle securely on an incline.

Reassembly

1. Install rear wheels and tighten lug nuts to proper torque specification in star pattern
2. Lower vehicle to ground and perform final lug nut torque verification
3. Reconnect 12V auxiliary battery negative terminal
4. Start vehicle and verify brake warning lights extinguish after system check
5. Check brake fluid level and top off to MAX line with fresh DOT 4 fluid
6. Pump brake pedal repeatedly (at least 20-30 times) to fully seat caliper pistons and establish proper pedal height
7. Verify firm brake pedal with no sponginess or excessive travel - if pedal is soft, additional bleeding is required

Verification

• With vehicle running, verify brake pedal is firm and does not sink when held under constant pressure for 30 seconds
• Check for any brake fluid leaks at caliper banjo bolt connections, bleeder valves, and around piston dust boots
• Test brakes at low speed in safe area - vehicle should stop smoothly without pulling to either side
• Verify electronic parking brake applies and releases properly with no warning lights
• Perform multiple moderate brake applications from 20-30 mph to properly bed-in new seals and verify even braking
• Scan for diagnostic trouble codes using Rivian diagnostic tool - no brake system codes should be present
• Road test vehicle in safe area, gradually increasing brake application force - brakes should feel firm and responsive with no pulsation, noise, or pulling
• After road test, re-inspect all caliper connections and surrounding areas for any signs of brake fluid leakage
• Schedule follow-up inspection after 50-100 miles to verify no leaks have developed and brake performance remains optimal
• CRITICAL: Do not return vehicle to service if there is ANY question about brake system integrity or performance

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle