Brake Rotor - Rear Single

This procedure covers removal and replacement of a single rear brake rotor on a 2025 Rivian EDV 500 electric delivery van, including caliper bracket removal and proper bedding recommendations.

Warnings

Tools required

Parts

• Rear brake rotor × 1 — Use OEM specification for EDV 500
• Caliper bracket bolts (if corroded) × 2 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake firmly
2. Chock the front wheels on both sides to prevent any vehicle movement
3. Verify vehicle is powered off and key fob is at least 20 feet away from vehicle
4. Loosen rear wheel lug nuts 1/4 turn while wheel is still on ground
5. Lift rear of vehicle using manufacturer-specified jacking points and secure on jack stands rated for commercial vehicle weight
6. Remove rear wheel completely and set aside
7. Inspect brake system for fluid leaks, damaged lines, or excessive corrosion before proceeding
8. If brake fluid reservoir is near MAX line, remove small amount with turkey baster to prevent overflow when compressing pistons

Procedure

1. 1

   Remove brake caliper
   Locate the two caliper slide bolts on the rear side of the caliper. Remove both bolts using appropriate socket. Carefully pivot caliper upward and off the rotor. Do NOT let caliper hang by brake hose - support it with wire hang or bungee cord attached to suspension component.
2. 2

   Inspect brake pads and hardware
   With caliper removed, note the position and orientation of brake pads and any anti-rattle clips or shims. Inspect pad thickness - if less than 3mm, replace pads during this service. Check caliper slides for smooth movement and adequate lubrication.
3. 3

   Remove caliper bracket
   Locate the two caliper bracket mounting bolts that attach bracket to the rear knuckle/spindle assembly. These are typically larger than caliper slide bolts. Remove both bolts completely and remove the entire bracket assembly. Note: These bolts are often very tight and may require breaker bar.
   ⚠Caliper bracket bolts are high-torque fasteners. Use proper 6-point sockets to avoid rounding bolt heads. Apply penetrating oil if bolts show corrosion.
4. 4

   Remove brake rotor
   Pull rotor straight off the wheel hub. If rotor is stuck due to corrosion, thread two appropriately sized bolts into the threaded holes on rotor face (if present) and tighten evenly to press rotor off hub. Alternatively, strike rotor face with rubber mallet between wheel studs. Never strike wheel studs or hub bearing area.
5. 5

   Clean hub mounting surface
   Use wire brush to thoroughly clean all rust, corrosion, and debris from wheel hub face where rotor mounts. Hub surface must be completely clean and flat to prevent rotor runout. Clean wheel studs and inspect for damage. Blow off all debris with compressed air or wipe clean.
6. 6

   Prepare and install new rotor
   Remove protective coating from new rotor using brake parts cleaner and lint-free cloth. Clean both sides thoroughly. Apply thin layer of anti-seize compound to hub mounting surface (not rotor friction surface). Slide new rotor onto hub, ensuring it sits completely flat. Use one lug nut to temporarily hold rotor in place during reassembly.
   ⚠Never touch rotor friction surfaces with oily or greasy hands. Contamination will cause reduced braking performance and noise.
7. 7

   Reinstall caliper bracket
   Position caliper bracket over rotor and align mounting holes with knuckle/spindle. Install both bracket bolts and tighten in a crossing pattern. Note: Torque specifications not available in database - consult Rivian service documentation for proper torque value, typically 80-120 ft-lbs for rear caliper brackets.
   ⚠️Caliper bracket bolts are CRITICAL safety fasteners. Without proper torque specifications, this repair cannot be completed safely. Obtain correct torque specification from Rivian service manual before proceeding.
8. 8

   Compress caliper pistons
   Before reinstalling caliper, pistons must be compressed to accommodate new rotor thickness. Use brake caliper piston tool or large C-clamp to slowly and evenly compress piston(s) into caliper bore. Watch brake fluid reservoir - it will rise as pistons compress. Remove excess fluid if necessary to prevent overflow.
9. 9

   Reinstall brake caliper
   Ensure brake pads are properly positioned in caliper bracket with anti-rattle hardware in place. Guide caliper down over rotor and into position on bracket. Install both caliper slide bolts and tighten. Note: Torque specifications not available in database - consult Rivian service documentation for proper torque value, typically 25-35 ft-lbs for caliper slide bolts.
10. 10

    Reinstall wheel and lower vehicle
    Remove temporary lug nut from rotor. Install wheel onto hub, ensuring it seats fully. Install all lug nuts hand-tight in star pattern. Lower vehicle until tire just touches ground but weight is still on jack stands. Torque lug nuts to specification in star pattern. Note: Torque specifications not available in database - consult Rivian service documentation, typically 150-180 ft-lbs for EDV 500.

Reassembly

1. Completely lower vehicle to ground and remove jack stands
2. Perform final torque check on all lug nuts in star pattern
3. Before moving vehicle, pump brake pedal several times until firm pedal is achieved - pistons must re-extend to contact pads
4. Check brake fluid level in reservoir and top off with DOT 4 brake fluid if needed to bring to MAX line
5. Start vehicle and verify brake warning light is not illuminated on dashboard

Verification

• With vehicle still stationary, press brake pedal firmly - it should feel solid and not sink to floor
• Test drive in safe area at low speed (5-10 mph) to verify brakes engage smoothly without pulling to one side
• Check for abnormal noises such as grinding, squealing, or rubbing during light brake applications
• Perform rotor bedding procedure: Make 30-50 controlled stops from 30 mph down to 5 mph with moderate pedal pressure, allowing 30 seconds between stops for cooling. Avoid complete stops when possible during bedding
• After bedding procedure and vehicle has cooled, inspect wheel area for any signs of fluid leakage or smoking
• Re-torque wheel lug nuts after first 50 miles of driving
• Monitor brake performance for first several hundred miles - any pulling, pulsation, or unusual noises require immediate inspection

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