Brake Pads and Rotors - Front

This procedure replaces the front brake pads and rotors on a 2025 Rivian EDV 500, including caliper service and proper bedding-in procedures for the electric vehicle's regenerative braking system.

Warnings

Tools required

Parts

• Front brake pad set (left and right) × 1 — Use OEM Rivian specification
• Front brake rotors × 2 — Use OEM Rivian specification
• Brake pad wear sensor (if equipped) × 2 — Check vehicle configuration
• Caliper slide pin grease × 1 — High-temperature synthetic brake grease
• Anti-seize compound × 1 — Copper or ceramic-based

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Using Rivian diagnostic software or OBD-II scanner, enter service mode to disable regenerative braking and retract electronic parking brake.
3. Disconnect 12V battery negative terminal located in front trunk (frunk) and wait 5 minutes for system capacitors to discharge.
4. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground.
5. Raise front of vehicle with floor jack at designated lift points (consult owner's manual for exact locations on frame rails).
6. Support vehicle with jack stands at reinforced jacking points. Shake vehicle to verify stability before working underneath.
7. Remove front wheels completely and set aside.
8. Verify brake fluid level in reservoir is between MIN and MAX marks. Do not proceed if fluid is at MAX (caliper compression will cause overflow).

Procedure

1. 1

   Inspect brake system and disconnect wear sensors
   Visually inspect the brake assembly for any damage, fluid leaks, or unusual wear patterns. If wear sensors are present, disconnect the electrical connector from the brake pad sensor by pressing the release tab and gently pulling apart. Note the routing of the sensor wire for reinstallation.
2. 2

   Remove caliper slide pins
   Using an 18mm wrench, remove the lower and upper caliper slide pin bolts. Support the caliper with one hand as you remove the second bolt to prevent it from falling. The caliper may be tight due to pad wear; carefully work it free from the rotor if necessary.
3. 3

   Support and secure caliper
   Carefully pivot the caliper up and off the rotor. Do NOT let the caliper hang by the brake hose as this can damage the hydraulic line. Use mechanics wire or a plastic tie to secure the caliper to the suspension or chassis, ensuring no tension on the brake hose.
4. 4

   Remove old brake pads and hardware
   Remove the old brake pads from the caliper bracket. Note the orientation and position of any anti-rattle clips, shims, or springs. Remove these components and inspect for damage or corrosion. Set aside any reusable hardware that is in good condition.
5. 5

   Remove caliper bracket
   Using a T55 Torx socket, remove the two caliper bracket mounting bolts that secure the bracket to the steering knuckle. These bolts are typically torqued to high specification and may require significant force to break loose. Remove the bracket completely to access the rotor.
   ⚠Caliper bracket bolts are torque-critical fasteners. Inspect threads for damage and replace if any stripping or cross-threading is evident.
6. 6

   Remove old rotor
   If present, remove any retaining clips or screws holding the rotor to the hub. The rotor may be seized to the hub due to corrosion. If stuck, tap the rotor from behind with a rubber mallet, rotating and tapping in multiple locations. Do not strike the rotor face or use excessive force that could damage wheel bearings.
7. 7

   Clean hub surface and prepare for new rotor
   Use a wire brush to clean the hub face where the rotor mounts, removing all rust, scale, and debris. Clean the hub surface with brake cleaner and wipe dry. Apply a thin coat of anti-seize compound to the hub face (avoiding the wheel stud threads). This prevents future rotor seizure and ensures proper rotor seating.
8. 8

   Install new rotor
   Remove any protective coating from the new rotor using brake cleaner and a clean cloth (both sides and edges). Position the new rotor onto the hub, aligning any holes for retaining screws or clips. If equipped, install rotor retaining hardware. Verify the rotor sits flush against the hub with no gaps or wobble.
9. 9

   Reinstall caliper bracket
   Position the caliper bracket over the rotor and align with the mounting holes on the steering knuckle. Apply a small amount of threadlocker to the T55 Torx bracket bolts (unless they are pre-coated). Install both bolts and torque to specification per Rivian service manual (typically 120-140 ft-lbs, but verify for this model). Torque in a cross pattern if possible.
   ℹ️Torque specification not available in database. Consult Rivian service manual or dealership for exact specification before proceeding. Incorrect torque can cause brake failure.
10. 10

    Prepare and install new brake pads
    Clean the caliper bracket contact points with brake cleaner and wire brush. Apply a thin layer of high-temperature brake grease to the caliper bracket areas where pads will slide. Install any anti-rattle clips, shims, or springs in their original positions. Install the new inner and outer brake pads into the caliper bracket, ensuring they are properly seated. Connect brake pad wear sensor if equipped.
11. 11

    Compress caliper piston
    Before compressing the piston, open the brake fluid reservoir cap slightly to prevent pressure buildup. Using a C-clamp or brake caliper compression tool, slowly and evenly compress the caliper piston(s) fully into the caliper bore. Watch the brake fluid reservoir and stop if fluid approaches the MAX line (remove fluid with a turkey baster if necessary). Close the reservoir cap when finished.
    ⚠Verify regenerative braking is disabled via diagnostic software before compressing caliper. Forcing pistons against an active system can damage the ABS hydraulic control unit.
12. 12

    Reinstall caliper
    Remove the wire or tie supporting the caliper. Carefully position the caliper over the new brake pads and rotor. Clean the caliper slide pins with brake cleaner and inspect for damage or excessive wear. Apply a thin coat of high-temperature caliper grease to the slide pin shafts (not the threads). Install and hand-tighten both slide pin bolts, then torque to specification using the 18mm wrench (typically 25-35 ft-lbs for slide pins).
    ℹ️Torque specification not available in database. Consult Rivian service manual for caliper slide pin torque specification.
13. 13

    Repeat for opposite side
    Perform steps 1 through 12 for the opposite front wheel, ensuring both sides have matching new pads and rotors. Consistency between sides is critical for balanced braking performance.
14. 14

    Reinstall wheels and lower vehicle
    Reinstall both front wheels, hand-tightening lug nuts in a star pattern. Lower the vehicle until tires just touch the ground but weight is still on jack stands. Torque lug nuts to specification in a star pattern (typically 130-150 ft-lbs for Rivian). Fully lower vehicle and remove jack stands. Perform final lug nut torque check with vehicle on ground.
    ℹ️Wheel lug torque specification not available in database. Consult owner's manual or service information for exact specification.
15. 15

    Restore vehicle systems and check brake fluid
    Reconnect the 12V battery negative terminal. Enter the vehicle and pump the brake pedal slowly 10-15 times until firm resistance is felt (this resets caliper piston position). Check brake fluid level in reservoir and top off with DOT 4 fluid if necessary to reach MAX line. Using diagnostic software, exit service mode to re-enable regenerative braking and electronic parking brake. Clear any brake service alerts or warnings.

Reassembly

1. Ensure all caliper bolts and slide pins are torqued to specification.
2. Verify brake fluid level is between MIN and MAX marks after pedal pumping.
3. Confirm all brake pad wear sensor connectors are properly connected if equipped.
4. Check that no tools or parts are left in wheel wells or under vehicle.
5. Verify wheels are torqued properly and lug nuts are secure.

Verification

• Before driving, pump brake pedal until firm and verify pedal does not sink to floor when held under pressure for 30 seconds.
• Perform a low-speed brake test (under 10 mph) in a safe area to verify brakes engage properly before road testing.
• Perform proper brake pad bedding procedure: Make 8-10 stops from 40 mph to 10 mph with moderate pressure, allowing 30 seconds between stops to cool. Do NOT come to complete stop during bedding. This transfers pad material to rotor surface.
• After bedding, allow brakes to cool for 10 minutes before normal driving.
• Monitor for any unusual noises, vibrations, or pulling during braking for the first 100 miles.
• Check for brake fluid leaks around calipers and brake lines after first drive.
• Verify regenerative braking system is functioning properly through vehicle display and normal braking feel.
• After 50-100 miles, re-torque wheel lug nuts and verify all caliper hardware remains secure.
• If brake warning light remains illuminated or brake pedal feel is abnormal, do not drive vehicle and consult qualified technician immediately.

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