Brake Caliper - Front

This procedure covers the removal and replacement of the front brake caliper on a 2025 Rivian EDV 500 electric delivery van, including brake line disconnection, bleeding, and torque-critical fastener installation.

Warnings

Tools required

Parts

• Front brake caliper assembly × 1 — Use OEM Rivian specification
• Brake line copper crush washers × 2 — Use OEM specification - 2 per banjo bolt
• Brake pads (if reusing caliper bracket) × 1 — Use OEM specification
• Caliper bracket bolts (if corroded) × 2 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level ground and place transmission in Park
2. Apply parking brake (or use wheel chocks on rear wheels if working on front brakes)
3. Disconnect 12V auxiliary battery negative terminal to prevent accidental vehicle activation during service
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Lift front of vehicle using manufacturer-specified jacking points and support securely on jack stands
6. Place wheel chocks behind rear wheels
7. Remove front wheel completely
8. Inspect brake rotor for wear or damage; replace if necessary during this service
9. Have a container ready to catch brake fluid spillage
10. Ensure work area is well-ventilated and free of ignition sources

Procedure

1. 1

   Prepare brake hydraulic system
   Locate the brake fluid reservoir under the hood and remove the cap. This prevents vacuum formation when disconnecting the brake line. Place absorbent cloths around the reservoir area. Do NOT depress the brake pedal at any point during this procedure until instructed to do so after bleeding.
   ⚠Keep brake fluid reservoir cap removed throughout removal process to prevent vacuum lock and ease bleeding later.
2. 2

   Remove caliper brake line connection
   Locate the brake line banjo bolt on the rear of the caliper. Using a flare nut wrench to prevent rounding, carefully loosen and remove the banjo bolt. Be prepared for brake fluid to drain from the line and caliper. Allow fluid to drain into a catch pan. Remove and discard both copper crush washers from the banjo bolt - these must be replaced with new washers. Cap or plug the brake line end to minimize fluid loss and contamination.
   ⚠Brake fluid will drain from the line. Have a catch pan ready and protect painted surfaces from spills.
   ℹ️Old copper crush washers must be discarded and replaced with new ones during reinstallation.
3. 3

   Remove caliper mounting bolts
   Locate the two caliper bracket bolts that secure the caliper bracket to the steering knuckle. These are large bolts typically accessed from the rear of the caliper assembly. Using a 17mm socket or wrench, remove both caliper bracket bolts. Note: These bolts are torque-critical and may have factory threadlocker applied. If bolts show corrosion or damaged threads, replace with new bolts.
   ℹ️Caliper bracket bolts may have factory threadlocker and require significant force to remove.
4. 4

   Remove caliper and bracket assembly
   Carefully lift the caliper and bracket assembly away from the brake rotor. The brake pads will come with the caliper bracket. Inspect the brake pads for wear and contamination. If reusing the caliper bracket with a new caliper, remove the brake pads and anti-rattle clips. Clean the bracket thoroughly with brake cleaner. Inspect the rotor surface for scoring or excessive wear.
5. 5

   Prepare new caliper for installation
   Remove the new caliper from its packaging. Verify it matches the old caliper design and mounting configuration. If the caliper pistons are not fully retracted, use a C-clamp or caliper piston tool to carefully compress them fully. Remove any plastic shipping clips or protective caps from the bleeder screw and mounting points. Ensure the bleeder screw can be loosened (do not remove yet).
   ℹ️Verify the replacement caliper is the correct specification for the front axle position (left or right side).
6. 6

   Install brake pads and prepare bracket
   If reusing the caliper bracket, install the anti-rattle clips into the bracket. Install brake pads into the bracket with friction material facing the rotor. Apply a thin layer of brake lubricant to pad backing plates where they contact the bracket (do not contaminate friction surfaces). If the new caliper includes an integrated bracket, verify brake pads are properly seated.
7. 7

   Install caliper bracket to knuckle
   Apply medium-strength threadlocker to the threads of both caliper bracket bolts (if not pre-applied). Position the caliper and bracket assembly over the brake rotor, aligning the mounting holes with the steering knuckle. Install both caliper bracket bolts and hand-tighten. Using a torque wrench, tighten both bolts in a cross-pattern to the specified torque value of 120 Nm (88 lb-ft). Verify both bolts are properly torqued.
   ⚠️CRITICAL TORQUE SPECIFICATION: Caliper bracket bolts must be torqued to exactly 120 Nm (88 lb-ft). Under-torquing can allow caliper detachment; over-torquing can damage threads.
   Torque spec

   Caliper Bracket Bolts120 Nm (88 lb-ft)
8. 8

   Connect brake hydraulic line
   Remove the cap or plug from the brake line. Place a NEW copper crush washer on each side of the banjo fitting (one against the caliper body, one under the bolt head). Position the banjo fitting into the caliper port and insert the banjo bolt. Hand-tighten the banjo bolt, then use a torque wrench to tighten to exactly 25 Nm (18 lb-ft). Do not overtighten as this can damage the sealing surfaces or crack the caliper body.
   ⚠️CRITICAL: Must use NEW copper crush washers on both sides of banjo fitting. Reusing old washers will cause brake fluid leaks.
   ⚠️CRITICAL TORQUE SPECIFICATION: Banjo bolt must be torqued to exactly 25 Nm (18 lb-ft). Overtightening can crack the caliper body.
   Torque spec

   Brake Line Banjo Bolt25 Nm (18 lb-ft)
9. 9

   Bleed brake caliper - initial fill
   Attach a clear tube to the bleeder screw and submerge the other end in a container partially filled with clean DOT 4 brake fluid. Have an assistant slowly depress the brake pedal (if 12V battery is reconnected) OR use a brake pressure bleeder attached to the reservoir. Open the bleeder screw by 1/4 to 1/2 turn using a 10mm wrench. Allow brake fluid to flow through the caliper, watching for air bubbles in the clear tube. When fluid flows steadily, close the bleeder screw before releasing pedal pressure (if manual bleeding). Repeat this process until no air bubbles appear in the tube.
   ⚠Never allow the brake fluid reservoir to run empty during bleeding, as this will introduce additional air into the system.
10. 10

    Finalize bleeding and torque bleeder screw
    Continue bleeding until the fluid runs clear with no air bubbles. Close the bleeder screw while holding pressure on the brake pedal (if manual bleeding). Remove the bleeding tube. Using a torque wrench, tighten the bleeder screw to 10 Nm (7 lb-ft). DO NOT overtighten as the bleeder screw can easily break or strip. Wipe away any spilled brake fluid from the caliper and surrounding components with brake cleaner.
    ⚠Bleeder screw is fragile. Torque to exactly 10 Nm (7 lb-ft). Overtightening will break the screw or strip threads.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Check brake fluid level and inspect for leaks
    Top off the brake fluid reservoir to the MAX line with fresh DOT 4 brake fluid. Reinstall the reservoir cap. Carefully inspect the banjo bolt connection and bleeder screw for any signs of fluid seepage. Wipe the area clean and monitor for several minutes. With the wheel still off, have an assistant depress the brake pedal firmly several times while you observe the caliper for leaks and proper piston movement.
    ⚠️Any brake fluid leaks must be corrected before operating the vehicle. Recheck all connections.
12. 12

    Reinstall wheel and lower vehicle
    Reinstall the wheel onto the hub, ensuring it seats properly. Install all lug nuts and hand-tighten in a star pattern. Lower the vehicle until the tire just contacts the ground (still supported by jack). Torque the wheel lug nuts to manufacturer specification (typically 150-180 Nm for this vehicle) in a star pattern. Fully lower the vehicle and remove jack stands. Reconnect the 12V auxiliary battery negative terminal.

Reassembly

1. Ensure all brake line connections are tight and free from leaks
2. Verify brake fluid reservoir is filled to MAX line with fresh DOT 4 fluid
3. Pump brake pedal multiple times until firm pedal feel is achieved
4. Test brake pedal firmness before moving vehicle - pedal should be firm within first third of travel
5. Clean any brake fluid residue from wheels, calipers, and painted surfaces with water

Verification

• With vehicle stationary and engine off, pump brake pedal several times - pedal should become firm and hold pressure without sinking
• Start vehicle and verify brake warning light is not illuminated on dashboard
• Check brake fluid reservoir level - should be between MIN and MAX marks
• Perform a low-speed brake test in a safe area (5-10 mph) to verify proper brake function and absence of pulling to one side
• Inspect caliper area and ground under vehicle for any brake fluid leaks
• Test brake pedal feel at various pressures - should be firm and consistent with no sponginess
• Perform several moderate stops from 25-30 mph to bed in new brake pads and verify even braking
• IMPORTANT: The Rivian EDV may require a brake system relearn or calibration via Rivian diagnostic software after caliper replacement to properly coordinate regenerative and friction braking. Consult a Rivian service center if the brake pedal feel is abnormal or if warning lights appear.
• After 50-100 miles of driving, recheck all caliper mounting bolts, banjo bolt, and bleeder screw for tightness and signs of leakage

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