Brake Caliper - Rear

Complete removal and replacement of the rear brake caliper on a 2025 Rivian EDV 500, including brake line disconnection, caliper mounting hardware removal, and system bleeding.

Warnings

Tools required

Parts

• Rear brake caliper assembly × 1 — Use OEM Rivian specification
• Copper crush washers for banjo bolt × 2 — Two washers per brake line connection
• Brake caliper bracket bolts (if corroded) × 2 — Use OEM specification
• DOT 4 brake fluid × 1 — 1 quart minimum for bleeding

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and place wheel chocks in front of front wheels
2. Place vehicle in Park mode and verify parking brake is engaged
3. Verify 12V battery is fully charged (brake bleeding requires power for ABS pump cycling)
4. Remove spare brake fluid reservoir cap briefly to check fluid level, then loosely replace (do not seal tight)
5. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
6. Lift rear of vehicle with floor jack at designated lift points per owner's manual
7. Install jack stands rated for EV weight at rear jacking points, then lower vehicle onto stands
8. Remove rear wheel completely and set aside
9. Inspect brake system for any signs of previous damage or modification

Procedure

1. 1

   Prepare brake line for disconnection
   Place drain pan under caliper area to catch brake fluid. Clean the brake line banjo bolt connection at the caliper with brake cleaner to prevent contamination. Identify the banjo bolt and two copper crush washers that seal the connection. Have replacement copper washers ready before proceeding.
2. 2

   Disconnect brake hydraulic line
   Using a flare nut wrench to prevent rounding, carefully loosen and remove the brake line banjo bolt. Immediately plug or cap the brake line end to minimize fluid loss and prevent contamination. Remove and discard both old copper crush washers. Brake fluid will drain - ensure drain pan is positioned correctly. Do not allow brake fluid to contact paint, wiring, or high-voltage components.
   ⚠Brake fluid will spray initially when bolt is loosened. Protect eyes and have rags ready.
3. 3

   Remove caliper mounting hardware
   Locate the two caliper bracket bolts that secure the caliper assembly to the rear knuckle or mounting bracket. These are large bolts typically requiring an 18mm socket. Using a breaker bar if needed, loosen both caliper bracket bolts. These bolts are torqued to 100 Nm and may require significant force to break loose.
4. 4

   Remove rear brake caliper
   Fully remove both caliper bracket bolts and set aside. If bolts show any corrosion or thread damage, replace with new OEM bolts. Carefully lift the entire caliper assembly away from the rotor and mounting bracket. The caliper will be heavy and may still have residual brake fluid inside. Inspect the rotor surface and brake pads if reusing pads with new caliper.
5. 5

   Inspect mounting surfaces and prepare new caliper
   Clean the caliper mounting bracket surfaces on the knuckle with brake cleaner and a wire brush. Remove any rust, debris, or old thread locker compound from the bracket bolt holes. Inspect the brake rotor for scoring, cracks, or excessive wear - replace if necessary. Verify the new caliper includes brake pads or transfer pads from old caliper if pads are in good condition. If transferring pads, ensure they are properly positioned in new caliper.
6. 6

   Compress caliper pistons if necessary
   If the new caliper pistons are extended, use a C-clamp or brake piston tool to carefully compress them fully into the caliper bore. This is necessary for the caliper to fit over the brake rotor. Compress slowly to avoid damaging piston seals. Note that some brake fluid may be pushed back toward the master cylinder - monitor the brake fluid reservoir and remove fluid with a turkey baster if it approaches maximum level.
   ⚠Do not open bleeder screw during piston compression or air will be introduced into the system.
7. 7

   Install new caliper assembly
   Position the new caliper over the brake rotor and align the mounting holes with the bracket on the knuckle. Apply medium-strength thread locker to the threads of both caliper bracket bolts. Insert both bracket bolts and hand-thread them to ensure proper alignment. Do not cross-thread the bolts.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
8. 8

   Torque caliper bracket bolts
   Using a torque wrench, tighten both caliper bracket bolts to exactly 100 Nm (74 lb-ft) in a cross pattern. This is a CRITICAL torque specification - undertightening can allow caliper movement resulting in brake failure, while overtightening can damage threads or brackets. Verify both bolts are properly torqued.
   ⚠️Incorrect torque on caliper bracket bolts can result in caliper detachment and complete brake failure.
   Torque spec

   Caliper Bracket Bolts100 Nm (74 lb-ft)
9. 9

   Reconnect brake hydraulic line
   Install two NEW copper crush washers onto the banjo bolt (one on each side of the banjo fitting). Position the brake line banjo fitting against the caliper port, ensuring proper alignment. Insert the banjo bolt through the fitting and start threading by hand into the caliper port. Verify washers are properly seated on both sides of the banjo fitting.
   ⚠️Failure to use new copper washers will result in brake fluid leaks and potential brake system failure.
10. 10

    Torque brake line banjo bolt
    Using a torque wrench with flare nut wrench or appropriate socket, tighten the brake line banjo bolt to exactly 25 Nm (18 lb-ft). This is a CRITICAL specification - overtightening will crush the copper washers excessively and cause leaks; undertightening will also cause leaks. After torquing, visually verify the connection is properly seated and copper washers are evenly compressed.
    ⚠️Incorrect torque on banjo bolt will cause brake fluid leaks and brake system failure.
    Torque spec

    Brake Line Banjo Bolt25 Nm (18 lb-ft)
11. 11

    Bleed rear caliper initial pass
    Locate the bleeder screw on the rear caliper (typically on top rear of caliper body). Clean the bleeder screw area thoroughly. Attach a clear hose to the bleeder screw and submerge the other end in a container with clean DOT 4 brake fluid. Have an assistant pump the brake pedal 5-10 times and hold pressure. Open the bleeder screw 1/4 to 1/2 turn and observe fluid flow. Close bleeder screw before pedal reaches floor. Repeat until fluid flows with minimal air bubbles.
    ⚠Never allow brake pedal to be released while bleeder screw is open, as this will draw air into the system.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
12. 12

    Perform complete brake system bleeding
    Following Rivian's recommended bleeding sequence (typically right rear, left rear, right front, left front), bleed all four corners of the brake system to ensure no air remains. Use a pressure bleeder if available for more efficient bleeding. Monitor brake fluid reservoir constantly and maintain level between MIN and MAX marks. Continue bleeding each corner until fluid runs clear with no air bubbles. The rear caliper you replaced should require the most bleeding cycles.
    ⚠️Air in brake lines will cause soft pedal and reduced braking performance. Complete bleeding is mandatory.
13. 13

    Final bleeder screw torque
    After bleeding is complete and while the last bleeder screw is closed, use a torque wrench to verify all bleeder screws (including the new rear caliper) are torqued to 10 Nm (7 lb-ft). Do not overtighten as bleeder screws are easily damaged. Wipe away any residual brake fluid from all caliper surfaces and the brake line connection.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
14. 14

    Reinstall wheel and test
    Reinstall the rear wheel onto the hub, hand-threading all lug nuts. Lower vehicle partially so tire contacts ground but weight is still on jack stands. Torque lug nuts to Rivian specification in a star pattern. Fully lower vehicle and remove jack stands. Pump brake pedal 10-15 times to seat caliper pistons against rotor. Pedal should become firm and hold steady pressure.

Reassembly

1. Top off brake fluid reservoir to MAX level with fresh DOT 4 brake fluid, ensuring cap is properly sealed
2. Inspect all brake line connections for any signs of fluid seepage - wipe dry and monitor for leaks
3. Check torque on all lug nuts after vehicle has been lowered to full weight
4. Verify parking brake operates correctly and releases fully

Verification

• With engine/vehicle powered on, pump brake pedal multiple times - pedal should become firm within 2-3 pumps and maintain height
• Apply steady firm pressure to brake pedal for 30 seconds - pedal should not sink or fade
• With vehicle powered on, verify no brake warning lights are illuminated on instrument cluster
• Perform low-speed brake test in safe area (under 10 mph) to verify braking function before road use
• Inspect caliper and brake line connection for any fluid leaks while assistant applies brake pressure
• Perform multiple medium-effort brake applications from 25 mph in safe location - vehicle should stop straight with no pulling
• After first 50 miles of driving, re-inspect brake line banjo bolt connection and caliper mounting bolts for any seepage or loosening
• If brake pedal feels soft, spongy, or travels too far, DO NOT DRIVE - repeat bleeding procedure or seek professional assistance
• Monitor brake system for first several days of operation and immediately address any changes in pedal feel or braking performance

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