This procedure covers the removal and replacement of the brake caliper bracket on a 2025 Rivian EDV 500 electric delivery van, including proper handling of the electronic parking brake system.

Warnings

Tools required

Parts

• Brake caliper bracket × 1 — Use OEM Rivian specification
• Caliper bracket mounting bolts × 2 — Use OEM specification if damaged
• Copper crush washers (if brake line disconnected) × 2 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level ground and ensure transmission is in Park
2. Disconnect the 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
3. Chock the wheels that will remain on the ground
4. Connect diagnostic tool and access electronic parking brake (EPB) service mode to retract EPB actuator
5. Loosen wheel lug nuts while vehicle is still on ground (do not remove)
6. Raise vehicle with floor jack at designated jacking point and secure with jack stands at appropriate support points
7. Remove wheel and tire assembly completely
8. Inspect brake components for additional wear or damage that may need attention
9. Have a drain pan ready to catch any brake fluid if lines must be disconnected

Procedure

1. 1

   Remove brake caliper
   Using appropriate socket, remove the two caliper mounting bolts (typically 13mm or 15mm). Slide the caliper off the rotor and brake pads. DO NOT allow the caliper to hang by the brake hose. Support it using a caliper hanger or secure it to the suspension with mechanics wire to prevent stress on the brake line.
2. 2

   Remove brake pads and hardware
   Remove the brake pads from the caliper bracket. Note the orientation and position of any anti-rattle clips, shims, or pad wear indicators for correct reinstallation. Remove any pad retaining clips or springs from the bracket.
3. 3

   Inspect for brake line interference
   Check if the brake caliper bracket removal requires disconnecting the brake hydraulic line. On most Rivian EDV configurations, the line has sufficient slack, but if the caliper cannot be moved far enough out of the way, mark the brake line connection orientation and prepare to disconnect it. If disconnecting, have a brake line plug ready to minimize fluid loss.
   ⚠If brake line must be disconnected, you will need to bleed the entire brake system after reassembly. Ensure you have the proper bleeding equipment and procedure before proceeding.
4. 4

   Remove caliper bracket mounting bolts
   Locate the two caliper bracket mounting bolts that secure the bracket to the steering knuckle or axle housing. These are typically larger bolts (17mm-19mm) located behind where the brake pads were positioned. These bolts are often torqued very tight and may require a breaker bar. Apply penetrating oil if bolts show corrosion. Remove both bolts completely and carefully remove the caliper bracket from the vehicle.
   ℹ️These bolts may have thread locker applied from the factory. Significant force may be required to break them loose.
5. 5

   Inspect mounting surfaces and hardware
   Thoroughly inspect the knuckle or axle mounting surface for damage, scoring, or corrosion. Check the removed bracket bolts for thread damage, stretching, or corrosion. Inspect the caliper bracket itself if reusing for cracks, wear, or damage to pad slide surfaces. Clean all mounting surfaces with a wire brush and brake cleaner.
6. 6

   Prepare new or replacement bracket
   If installing a new bracket, verify it matches the removed component exactly. Clean all mounting surfaces on the new bracket. Apply a thin coat of anti-seize compound to the bolt threads (avoid getting anti-seize on bolt heads or friction surfaces). If reusing bracket, clean all pad contact surfaces and apply brake-specific lubricant to slide points per manufacturer specifications.
7. 7

   Install caliper bracket
   Position the new or serviced caliper bracket onto the knuckle or axle mounting points. Start both mounting bolts by hand to ensure proper thread engagement. Verify bracket is properly seated and aligned before tightening. Apply medium-strength thread locker to bolt threads if specified by manufacturer.
   ⚠️You MUST obtain and apply the correct factory torque specification for caliper bracket bolts before operating the vehicle. Insufficient torque can allow bracket separation during braking, causing complete brake failure.
8. 8

   Torque caliper bracket bolts
   Using a calibrated torque wrench, tighten the caliper bracket mounting bolts to the manufacturer's specified torque in a cross pattern (alternating between bolts). Since factory specifications are not available in this database, you must obtain the exact torque value from Rivian service documentation before performing this step. Typical values range from 70-110 ft-lbs, but this MUST be verified. After torquing, mark or verify bolt position.
   ⚠️DO NOT proceed without verified torque specifications. Over-torquing can damage threads or the bracket; under-torquing can allow bracket detachment during braking.
9. 9

   Reinstall brake pad hardware and pads
   Install any anti-rattle clips, shims, and pad retaining hardware onto the caliper bracket in their original positions. Install brake pads in the correct orientation, ensuring any wear indicators face the proper direction (typically toward the rear of the vehicle on the inner pad). Verify pads slide freely in the bracket channels.
10. 10

    Reinstall brake caliper
    If brake line was disconnected, reconnect it now with new copper crush washers and torque to specification. Position the caliper over the brake pads and bracket. Install caliper mounting bolts and tighten to manufacturer specification (typically 25-35 ft-lbs for caliper-to-bracket bolts, but verify). Ensure caliper is properly seated and moves freely on its slide pins if applicable.
11. 11

    Bleed brake system if opened
    If the brake hydraulic line was disconnected, the brake system must be bled to remove all air. Follow Rivian's specified bleeding procedure for the EDV 500, which may require the diagnostic tool to activate the ABS pump. Start with the wheel furthest from the master cylinder and work toward the closest. Bleed until fluid runs clear with no air bubbles.
    ⚠️Air in the brake lines will cause partial or complete brake failure. The system MUST be properly bled if any hydraulic connections were opened.
12. 12

    Reinstall wheel and lower vehicle
    Reinstall the wheel and tire assembly. Start all lug nuts by hand, then tighten in a star pattern while vehicle is still on jack stands. Lower vehicle to the ground, then torque lug nuts to specification (typically 130-150 ft-lbs for the EDV 500, but verify) in a star pattern using a torque wrench.
13. 13

    Reset EPB and restore electrical
    Using the diagnostic tool, exit EPB service mode and perform EPB initialization/calibration procedure as specified by Rivian. Reconnect the 12V battery negative terminal. Turn vehicle to ON position and verify no brake system warning lights remain illuminated after system initialization completes.

Reassembly

1. Always replace caliper bracket bolts if they show any signs of thread damage or excessive corrosion
2. Never reuse copper crush washers on brake line connections
3. Apply brake-specific high-temperature lubricant only to pad slide points and caliper slide pins, never to friction surfaces
4. Ensure all brake hardware is reinstalled in original positions and orientations
5. Double-check that no tools or parts are left in the wheel well before reinstalling the wheel

Verification

• With vehicle still in Park and on level ground, pump the brake pedal several times until it feels firm and normal resistance is achieved
• Check brake fluid reservoir level and top off with DOT 4 fluid if needed (do not overfill)
• Verify no brake warning lights are illuminated on the instrument cluster
• Test electronic parking brake engagement and release function multiple times to ensure proper operation
• Perform a low-speed test drive in a safe area (5-10 mph) to verify proper brake function before normal operation
• Perform several moderate brake applications from 20-30 mph in a safe area to seat the pads and verify even braking
• Listen for any unusual noises during brake application (grinding, squealing, or clicking may indicate installation issues)
• Check for brake fluid leaks around all connections after test drive
• Verify proper brake pedal feel with no excessive travel or sponginess
• Re-torque wheel lug nuts after 50-100 miles of driving

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