Brake Rotors - Rear Pair

Replace the rear brake rotors on a 2025 Rivian EDV 500, including removal of wheels, brake calipers, and caliper brackets to access and install new rotors.

Warnings

Tools required

Parts

• Rear brake rotor × 2 — Use OEM or high-quality aftermarket to Rivian EDV 500 specification
• Caliper bracket mounting bolts (if corroded) × 4 — Use OEM specification
• Rotor set screws (if equipped) × 4 — M6 x 1.0 x 10mm

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground and turn off the vehicle completely using the power button
2. Engage the electronic parking brake initially, then prepare to release it via service mode
3. Verify the vehicle is in Park mode
4. Place wheel chocks in front of the front wheels
5. Connect an OBD-II scan tool or access Rivian service mode through the vehicle touchscreen to place the electronic parking brake in service/maintenance mode
6. Loosen rear wheel lug nuts 1/4 turn while wheels are still on the ground
7. Lift the rear of the vehicle using a floor jack at the designated rear jacking points per owner's manual
8. Install jack stands at the proper support points and lower vehicle onto stands
9. Remove rear wheels completely and set aside
10. Inspect the brake system for any leaks, damage, or abnormal wear patterns
11. Have a drain pan ready in case any brake fluid drips during the procedure

Procedure

1. 1

   Access and inspect brake components
   With the wheel removed, visually inspect the brake caliper, rotor, and pad condition. Check for any signs of uneven wear, cracks in the rotor, or fluid leaks. Note the position of the brake pad wear sensor wire if equipped. Take photos if needed for reference during reassembly.
2. 2

   Prepare electronic parking brake system
   Confirm the electronic parking brake is in service mode through the scan tool or vehicle interface. This allows the caliper piston to be retracted without damaging the parking brake motor. If service mode is not available, you may need to disconnect the parking brake motor connector (typically located on the rear of the caliper).
3. 3

   Remove brake caliper
   Locate the two caliper slide pin bolts (typically 18mm) on the rear of the caliper. Remove both bolts completely. Carefully lift the caliper off the rotor and bracket. Do NOT allow the caliper to hang by the brake hose. Secure the caliper to the suspension or chassis using wire or a bungee cord, keeping it at or above rotor height to prevent hose stress.
   ⚠Support the caliper immediately after removal. Hanging weight on the brake hose can cause internal damage and brake failure.
4. 4

   Remove caliper bracket
   Locate the two caliper bracket mounting bolts (typically 19mm or 21mm) that secure the bracket to the hub assembly. These bolts are usually very tight. Use a breaker bar if necessary. Remove both bolts completely and remove the caliper bracket. Set aside hardware in a clean area.
5. 5

   Remove old rotor
   If present, remove any rotor retaining screws (typically Phillips or small hex). These may be corroded and difficult to remove; apply penetrating oil and allow to soak if needed. Once screws are removed (or if none are present), pull the rotor straight off the hub. If the rotor is stuck due to rust or corrosion, tap it from behind with a rubber mallet alternating around the rotor to break it free. Do not use excessive force that could damage wheel studs.
6. 6

   Clean hub mounting surface
   Using a wire brush, thoroughly clean the hub face where the rotor mounts. Remove all rust, corrosion, and debris. The mounting surface must be completely clean and flat to ensure the new rotor sits properly and runs true. Clean the wheel studs as well. Wipe the surface clean with brake cleaner and allow to dry.
7. 7

   Prepare new rotor
   Remove the new rotor from packaging. New rotors typically have a protective oil coating to prevent rust during storage. Clean both sides of the rotor thoroughly with brake cleaner and wipe dry with a clean, lint-free cloth. Ensure no oil, grease, or fingerprints remain on the rotor friction surfaces.
   ⚠Failure to remove the protective coating from new rotors will cause poor braking performance and may create hazardous driving conditions.
8. 8

   Install new rotor
   Slide the new rotor onto the hub, aligning the holes in the rotor with the wheel studs. Ensure the rotor is seated flush against the hub face with no gaps. If equipped, install new rotor retaining screws and tighten them snugly (these are just to hold the rotor during installation and are not critical fasteners). You may temporarily install one lug nut to hold the rotor in place during caliper bracket installation.
9. 9

   Reinstall caliper bracket
   Position the caliper bracket over the rotor and align with the mounting holes on the hub assembly. Install both caliper bracket mounting bolts and hand-tighten. Using a torque wrench, tighten the bracket bolts to the manufacturer's specification (obtain from Rivian service documentation - typically 80-95 ft-lbs for this class of vehicle, but verify). Tighten in a crosswise pattern if possible.
10. 10

    Retract caliper piston
    Before reinstalling the caliper, the piston must be retracted to accommodate the new, thicker rotor. With the parking brake in service mode, use a C-clamp or brake caliper piston tool to slowly compress the piston back into the caliper bore. For electronic parking brake calipers, you may need to use a specialized tool that rotates the piston while compressing it. Watch the brake fluid reservoir in the engine bay - it may overflow as the piston is compressed. Remove fluid as needed with a turkey baster or fluid pump.
    ⚠Compressing the caliper piston forces brake fluid back into the reservoir. Monitor the reservoir to prevent overflow, which can damage paint and other components.
11. 11

    Reinstall brake caliper
    Remove the caliper from its supported position. Verify the brake pads are properly seated in the bracket. Carefully position the caliper over the new rotor and bracket, aligning the slide pin bolt holes. Install both caliper slide pin bolts and hand-tighten. Torque the slide pin bolts to manufacturer specification (obtain from Rivian documentation - typically 25-35 ft-lbs for slide pins). Ensure the caliper moves freely on the slide pins.
12. 12

    Repeat for opposite side
    Repeat steps 1 through 11 for the opposite rear wheel. It is essential to replace rotors in pairs (both rear rotors) to maintain balanced braking performance. Never replace only one rotor.
13. 13

    Reinstall wheels
    Remove any temporary lug nuts used to hold rotors. Position each wheel onto the hub and install all lug nuts hand-tight in a star pattern. Lower the vehicle slightly so the wheels contact the ground but the suspension is not fully loaded. Torque the lug nuts to manufacturer specification (obtain from Rivian documentation - typically 110-130 ft-lbs for this vehicle) in a star pattern. Remove jack stands and lower vehicle completely.
14. 14

    Exit service mode and restore parking brake
    Using the scan tool or vehicle interface, exit the electronic parking brake service mode. The system should perform a self-calibration. If you disconnected any parking brake motor connectors, reconnect them now. Test the electronic parking brake engagement and release from the driver's seat to ensure proper function.
15. 15

    Pump brake pedal and check fluid level
    Before moving the vehicle, sit in the driver's seat and pump the brake pedal several times until it feels firm. This restores hydraulic pressure to the calipers. Check the brake fluid reservoir and top off with DOT 4 brake fluid if needed to bring level to the MAX line. Replace reservoir cap securely.

Reassembly

1. All components should be reassembled in reverse order of removal
2. Ensure all fasteners are torqued to manufacturer specifications - obtain these from official Rivian service documentation
3. Double-check that wheel lug nuts are torqued properly in a star pattern
4. Verify brake fluid level is between MIN and MAX marks in the reservoir
5. Confirm electronic parking brake has been taken out of service mode and functions normally

Verification

• Start the vehicle and verify no warning lights appear on the dashboard related to brakes or parking brake
• Test the electronic parking brake engagement and release multiple times from a stop
• Before driving, pump the brake pedal multiple times - it should feel firm and not sink to the floor
• Perform a low-speed brake test in a safe area (private lot or driveway) at 5-10 mph to verify brakes engage smoothly with no grinding, pulling, or pulsation
• Perform a moderate-speed brake test (15-25 mph) in a safe area to verify proper braking force and straight-line stopping
• Listen for any abnormal noises during the first few brake applications (light squeaking is normal during break-in)
• Bedding procedure: Perform 8-10 stops from 40 mph to 15 mph with moderate pressure, allowing 30 seconds between stops to cool. Then perform 3-4 stops from 50 mph to 20 mph with firm pressure. Allow brakes to cool for 5-10 minutes without coming to a complete stop if possible
• Check for vibration during braking - if present, verify rotors are properly seated and wheel lug nuts are torqued correctly
• After 50-100 miles, recheck wheel lug nut torque
• Monitor brake performance for the first 200-300 miles during the break-in period - braking effectiveness will improve as pads and rotors mate

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