This procedure covers the complete rebuild of front brake calipers on the 2025 Rivian EDV 500, including disassembly, inspection, seal replacement, and bleeding.

Warnings

Tools required

Parts

• Front brake caliper rebuild kit (includes seals, boots, and hardware) × 2 — Use OEM Rivian specification
• Copper crush washers for brake line banjo bolts × 4 — Use OEM specification
• Brake caliper slide pin boots (if deteriorated) × 4 — Usually included in rebuild kit

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Power down the vehicle completely and ensure it remains off throughout the procedure
2. Chock rear wheels securely on level ground
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise vehicle with floor jack at manufacturer-specified lift points and secure on jack stands rated for EV weight
5. Remove front wheels completely
6. Inspect brake system for unusual wear patterns or damage that may indicate other issues
7. Have fire extinguisher accessible when working on electric vehicles
8. Prepare clean workspace with lint-free surface for caliper disassembly
9. Open but do not remove brake fluid reservoir cap to prevent vacuum formation during caliper removal

Procedure

1. 1

   Remove brake caliper from vehicle
   Using a brake line wrench, loosen the banjo bolt connecting the brake hose to the caliper. Position a drain container beneath the caliper. Remove the banjo bolt completely and immediately cap or plug the brake line to minimize fluid loss and contamination. Remove the caliper slide pin bolts (typically two bolts securing caliper to bracket). Lift caliper away from rotor and bracket. Place caliper on clean work surface.
2. 2

   Remove brake pads and hardware
   Remove brake pads from caliper bracket if still installed. Remove any anti-rattle clips, shims, or hardware from the caliper bracket. Inspect bracket for wear or damage. If rebuilding only the caliper body and not removing the bracket, you may leave bracket installed on the vehicle. Note the position and orientation of all hardware for reassembly.
3. 3

   Remove caliper pistons
   Place caliper on workbench with piston facing up. Using compressed air at regulated 30 psi maximum, carefully apply air pressure to the brake fluid inlet port. The piston will begin to move outward. Control the piston with your hand or a shop rag to prevent it from ejecting forcefully. Remove piston completely. For multi-piston calipers, repeat for each piston. Alternatively, use a plastic piston removal tool to carefully pry pistons out if compressed air is unavailable.
   ⚠Pistons can eject with considerable force. Keep hands clear of the piston path and use controlled air pressure. Wear safety glasses.
4. 4

   Remove old seals and clean caliper bore
   Using a plastic pick or seal removal tool (never metal tools that can scratch the bore), carefully remove the piston seal from the groove inside the caliper bore. Remove the dust boot seal from the outer groove. Inspect the caliper bore for scoring, pitting, or corrosion. Thoroughly clean the bore, piston, and all internal caliper passages with brake parts cleaner and lint-free rags. Remove all old seal material, corrosion, and contaminants.
5. 5

   Inspect pistons and caliper bores
   Examine each piston for scoring, pitting, chrome plating damage, or corrosion. Measure piston diameter with a micrometer at multiple points. Check caliper bore diameter. Compare measurements to manufacturer specifications if available. Any scoring deeper than 0.001 inch or chrome plating damage requires piston replacement. Any bore scoring, pitting, or out-of-round condition beyond specifications requires caliper replacement, not rebuild. Use brass wire brush to clean caliper mounting surfaces and slide pin bores.
   ⚠Do not attempt to rebuild a caliper with damaged bores or pistons. This will result in brake failure. Replace the entire caliper if components are beyond specification.
6. 6

   Install new piston seals
   Verify all components from the rebuild kit match the caliper configuration. Apply a thin film of clean DOT 4 brake fluid to the new piston seal. Carefully install the seal into the groove in the caliper bore, ensuring it seats completely and evenly without twisting. The seal should sit flat in the groove with no portion protruding. Inspect seal placement by rotating your finger around the entire circumference.
7. 7

   Install new dust boots and pistons
   Apply clean DOT 4 brake fluid to the new dust boot and install it in the outer groove of the caliper bore (if design requires boot installation before piston). Lubricate the piston with clean brake fluid. Carefully insert the piston into the bore, ensuring it does not damage or dislodge the piston seal. Push the piston in straight and evenly. If dust boot installs after piston, seat it over the piston and into the caliper groove once piston is inserted. Ensure dust boot is fully seated with no tears or folds.
8. 8

   Service caliper slide pins
   Remove caliper slide pins from the bracket. Inspect pins for corrosion, wear, or damage. Inspect pin boots for tears or deterioration. Clean pins thoroughly with brake cleaner. Apply a thin coat of high-temperature silicone brake grease to the pins (use only brake-specific grease, not general purpose grease). Install new slide pin boots if originals are damaged. Reinstall pins into bracket, ensuring they move freely.
9. 9

   Reinstall caliper to vehicle
   Position rebuilt caliper over brake rotor and align with mounting bracket. Install caliper slide pin bolts and tighten to approximately 25-35 ft-lb (verify with Rivian specifications if available). Connect brake hose to caliper using new copper crush washers on both sides of the banjo fitting. Tighten banjo bolt to approximately 18-22 ft-lb. Do not overtighten as this can crack the caliper body.
10. 10

    Bleed brake system - front circuit
    Fill brake fluid reservoir to MAX line with fresh DOT 4 brake fluid. Attach a clear hose to the brake bleeder valve on the caliper and submerge the other end in a container of clean brake fluid. Have an assistant pump the brake pedal several times and hold pressure, or use a pressure bleeder. Open bleeder valve and observe fluid flow. Close valve before pedal reaches the floor. Repeat until fluid runs clear with no air bubbles. Typical bleeding sequence for this vehicle is: right front, left front, right rear, left rear. Bleed both front calipers thoroughly.
    ⚠️Air in the brake system will cause brake failure. Bleeding must be thorough and complete. Pedal must feel firm before operating vehicle.
11. 11

    Install brake pads and complete reassembly
    Install anti-rattle clips and hardware to caliper bracket in their original positions. Apply thin coat of brake grease to pad backing plate contact points (not on friction material). Install brake pads in correct orientation. Verify pads move freely in bracket. Reinstall wheels and hand-tighten lug nuts. Lower vehicle to ground and torque lug nuts to manufacturer specification (typically 130-140 ft-lb for this vehicle class) in a star pattern.

Reassembly

1. Verify brake fluid reservoir is at MAX level with fresh DOT 4 fluid
2. Inspect all brake line connections for leaks
3. Ensure caliper slide pins move freely and are properly lubricated
4. Confirm brake pads are correctly oriented and fully seated
5. Double-check all fasteners are tightened to specification
6. Wheel lug nuts must be torqued in star pattern to ensure even mounting

Verification

• With vehicle still on jack stands and in Park, pump brake pedal repeatedly. Pedal should become firm within 3-4 pumps and hold steady pressure. Spongy or sinking pedal indicates air in system or leak.
• Inspect all brake line connections and caliper seals for fluid seepage while assistant holds brake pedal pressure
• Lower vehicle and perform multiple stationary brake applications with heavy pedal pressure. Pedal feel should be firm and consistent.
• Perform low-speed test drive in safe area (under 15 mph). Test braking gradually increasing pressure. Brakes should engage smoothly without pulling to one side.
• Perform several moderate stops from 30-40 mph to seat brake pads and verify proper operation
• After test drive, recheck brake fluid level and inspect for leaks at all connections
• Monitor brake performance for first 100 miles and check fluid level after first 50 miles
• If any abnormal noise, vibration, pulling, or reduced braking performance occurs, immediately stop driving and reinspect all work

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