Brake Rotors - Front Pair

This procedure covers the removal and replacement of the front brake rotors on a 2025 Rivian EDV 500 Dual Motor AWD electric delivery van, including caliper removal and proper brake system verification.

Warnings

Tools required

Parts

• Front brake rotor × 2 — Rivian OEM or equivalent 375mm rotor
• Brake rotor set screws × 2 — M6 x 1.0 if equipped
• Brake caliper bracket bolts × 4 — Use OEM specification - Grade 10.9

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level ground and engage parking brake firmly
2. Power off the vehicle completely and remove key card from vehicle vicinity
3. Chock rear wheels securely on both sides
4. Loosen front wheel lug nuts (1/2 turn) while vehicle is on ground - do not remove yet
5. Lift front of vehicle using floor jack at designated front lift point behind front bumper
6. Place jack stands under frame rails at manufacturer-specified jacking points
7. Lower vehicle onto jack stands and verify stability before working underneath
8. Remove front wheels completely and set aside
9. Inspect brake fluid level in reservoir - should be at MAX line; if low, investigate for leaks before proceeding
10. Spray brake caliper bolts and rotor contact surfaces with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Disconnect brake wear sensor (if equipped)
   Locate the brake pad wear sensor connector on the inboard side of the caliper. Press the locking tab and carefully disconnect the electrical connector. Secure the connector away from the work area to prevent damage. Some EDV 500 models may not have wear sensors on front brakes.
2. 2

   Compress brake caliper piston
   Before removing the caliper, open the brake fluid reservoir cap slightly to relieve pressure. Using a C-clamp or brake piston compressor tool, slowly compress the caliper piston back into its bore. This creates clearance for removal and makes reinstallation easier. Watch the brake fluid reservoir and do not allow it to overflow. Close reservoir cap when piston is compressed.
   ⚠Compress piston slowly to avoid forcing contaminated fluid back into ABS system. If fluid is dark or contaminated, consider a complete brake fluid flush.
3. 3

   Remove brake caliper mounting bolts
   Locate the two caliper slide pin bolts on the rear of the caliper assembly. These are typically 18mm bolts. Using a socket and ratchet, remove both caliper mounting bolts completely. Keep track of any shims or hardware. Note: Do NOT remove the caliper bracket bolts yet - only the caliper slide pins.
   ℹ️Manufacturer torque specifications not available in database. Record original bolt torque during removal or consult Rivian service documentation before reassembly.
4. 4

   Remove and secure brake caliper
   Carefully lift the brake caliper straight up and off the rotor and bracket. Do NOT let the caliper hang by the brake hose. Use a caliper hanger, wire, or bungee cord to suspend the caliper from the suspension or frame. Ensure no tension or stress is placed on the flexible brake hose.
   ⚠️Never allow brake caliper to hang from brake hose. This can damage the hose internally and cause brake failure.
5. 5

   Remove caliper bracket
   Locate the two large caliper bracket mounting bolts that secure the bracket to the steering knuckle. These bolts are significantly larger than the caliper slide pins and require higher torque. Remove both bracket bolts completely using appropriate socket (likely 18mm or 21mm). Remove the caliper bracket assembly. Inspect bracket for wear, cracks, or damage.
   ℹ️Caliper bracket bolts are high-strength fasteners. Manufacturer torque specifications not available in database - consult Rivian service manual for proper torque values (typically 120-150 ft-lb for this weight class).
6. 6

   Remove brake rotor retaining screw (if equipped)
   Some Rivian EDV models use a small Phillips or Torx screw to retain the rotor during assembly. If present, remove this screw. If seized, apply penetrating oil and use an impact driver to prevent stripping. This screw is not critical for rotor retention once wheel is installed.
7. 7

   Remove old brake rotor
   Pull the brake rotor straight off the wheel hub. If rotor is stuck due to corrosion, tap the rotor from behind with a rubber mallet in multiple locations. Do not strike rotor mounting surface. If severely stuck, thread appropriate bolts into the threaded holes in the rotor hat (if equipped) and tighten evenly to push rotor off hub.
8. 8

   Clean hub mounting surface
   Using a wire brush, thoroughly clean the wheel hub mounting surface, removing all rust, scale, and debris. Clean the hub face where the rotor seats to ensure proper rotor mounting. Remove any corrosion from the wheel studs. This step is critical for proper rotor seating and preventing runout. Wipe clean with brake parts cleaner.
9. 9

   Install new brake rotor
   Remove any protective coating from new rotor surfaces using brake parts cleaner. Apply a thin coat of anti-seize compound to the hub face (not rotor braking surface). Slide new rotor onto wheel hub, aligning holes with wheel studs. Ensure rotor seats fully flush against hub. If equipped, install rotor retaining screw and tighten snugly (do not overtighten - approximately 35 in-lb).
   ⚠Ensure rotor directional arrows (if present) point in the direction of wheel rotation. Some performance rotors are directional.
10. 10

    Reinstall caliper bracket
    Position caliper bracket over rotor and align mounting holes with steering knuckle. Apply threadlocker (medium strength) to bracket bolt threads if specified by manufacturer. Install both bracket bolts and torque to specification. Without manufacturer specs, tighten firmly and evenly (estimated 120-150 ft-lb for commercial vehicle application, but verify with Rivian documentation).
    ⚠️Caliper bracket bolts are critical safety fasteners. Improper torque can result in brake failure. Consult Rivian service documentation for exact torque specification before proceeding.
11. 11

    Reinstall brake caliper
    Remove caliper from hanger/support. Ensure brake pads are properly seated in caliper. Carefully position caliper over new rotor and align with caliper bracket slide pins. Install both caliper slide pin bolts and tighten to specification. Without manufacturer specs, use moderate torque (estimated 30-45 ft-lb, but verify with Rivian documentation).
12. 12

    Reconnect brake wear sensor
    If brake wear sensor was disconnected in step 1, reconnect the electrical connector ensuring it clicks securely into place. Route wiring properly away from rotating components and heat sources. Verify connector is fully seated.
13. 13

    Repeat for opposite side
    Repeat steps 1-12 for the opposite front wheel to replace the second front rotor. Always replace brake rotors in axle pairs to maintain balanced braking performance.
14. 14

    Reinstall wheels and restore brake pedal
    Reinstall front wheels, hand-tightening lug nuts in star pattern. Raise vehicle slightly off jack stands, remove stands, and lower vehicle to ground. Torque wheel lug nuts to specification in star pattern (typically 150 ft-lb for commercial vehicle - verify with Rivian specs). Before moving vehicle, pump brake pedal slowly multiple times until firm pedal is achieved. Check brake fluid level and top off with DOT 4 fluid if needed.
15. 15

    Perform bedding procedure
    New rotors require proper bedding to transfer pad material evenly. In a safe area with no traffic, perform 8-10 moderate stops from 40-45 mph down to 15 mph with moderate pedal pressure. Allow 30-60 seconds between stops for cooling. Avoid complete stops during bedding. After bedding sequence, drive normally for several miles to allow brakes to cool completely before aggressive braking.
    ⚠Do not perform hard stops during initial 200 miles of rotor break-in. Aggressive braking before proper bedding can cause uneven pad deposits and brake judder.

Reassembly

1. All fasteners must be torqued to manufacturer specifications - consult Rivian service documentation for exact values
2. Brake caliper bracket bolts are critical safety fasteners and must be replaced if threads show any damage or stretching
3. Ensure brake fluid reservoir is filled to MAX line with fresh DOT 4 brake fluid
4. Verify brake wear sensor connectors are fully seated and secured away from moving parts
5. Double-check that all tools and hardware have been removed from wheel wells before test drive

Verification

• Before driving, pump brake pedal 10-15 times and verify firm pedal with no excessive travel or sponginess
• Check brake fluid level - should be at MAX line with no leaks visible
• Start vehicle and verify no brake system warning lights or messages appear on dashboard
• Perform low-speed brake test in safe area (parking lot) to verify normal brake function before driving on road
• Test drive at low speed and verify smooth, even braking with no pulsation, noise, or pulling to one side
• After 50-100 miles, re-check wheel lug nut torque and brake fluid level
• Monitor brake performance for first 200 miles - any unusual noise, vibration, or reduced stopping power requires immediate professional inspection
• Verify regenerative braking system continues to function normally (this procedure should not affect regen system)

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