This procedure covers the replacement of front brake pads on the 2025 Rivian EDV 500 electric delivery van, including caliper service and brake system verification.

Warnings

Tools required

Parts

• Front brake pad set (left and right) × 1 — Use OEM Rivian specification
• Brake pad retaining clips/hardware kit × 1 — Use OEM Rivian specification
• Brake caliper slide pin grease × 1 — High-temperature synthetic brake grease

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid ground and ensure gear selector is in Park
2. Verify battery is fully charged (brake service mode requires power)
3. Connect diagnostic scan tool and verify communication with vehicle systems
4. Place wheel chocks behind rear wheels
5. Remove approximately 1/3 of brake fluid from master cylinder reservoir using turkey baster to prevent overflow when compressing caliper pistons
6. Loosen front wheel lug nuts while vehicle is still on ground (approximately 1/4 turn)
7. Raise front of vehicle using floor jack at designated lift points per Rivian service manual
8. Install jack stands at proper support points on frame rails, ensuring vehicle is stable
9. Remove front wheels completely and set aside in safe location

Procedure

1. 1

   Enter Electronic Parking Brake Service Mode
   Using the diagnostic scan tool, navigate to the brake system module and select 'EPB Service Mode' or 'Brake Pad Replacement Mode'. This will retract the electronic parking brake actuators and allow caliper pistons to be compressed. Follow scan tool prompts to activate service mode. Verify on the scan tool display that service mode is active before proceeding. This step is critical for the EDV 500's integrated brake-by-wire system.
2. 2

   Inspect Brake Components
   Visually inspect the brake rotor for scoring, cracks, or excessive wear. Measure rotor thickness if possible and compare to Rivian specifications (consult service manual for minimum thickness). Inspect brake caliper for fluid leaks, damage, or seized slide pins. Check brake hose for cracks, bulging, or damage. If any components show excessive wear or damage, additional parts replacement may be required beyond pads.
3. 3

   Remove Caliper Retaining Bolts
   Locate the two caliper slide pin bolts (typically on the rear/inboard side of the caliper). Using the appropriate socket, remove the lower caliper bolt completely. Remove the upper caliper bolt completely. Keep bolts in a clean location. If bolts are excessively corroded or difficult to remove, apply penetrating oil and allow to soak before forcing.
4. 4

   Remove Brake Caliper
   Carefully pivot the caliper upward and away from the brake rotor. The caliper will still be attached to the brake hose - do NOT allow it to hang by the hose. Support the caliper using a wire hanger or bungee cord attached to the suspension or frame. Position the caliper so there is no tension on the brake hose. Inspect the brake hose connection at the caliper for any signs of leakage.
5. 5

   Remove Old Brake Pads and Hardware
   Remove the inner and outer brake pads from the caliper bracket. Note the orientation and position of each pad (inner pad may have a wear sensor connector on some variants). Remove any anti-rattle clips, shims, or springs from the caliper bracket. Clean the caliper bracket mounting surfaces thoroughly using brake cleaner and a wire brush, removing all rust, debris, and old brake dust. Do not use compressed air.
6. 6

   Inspect and Lubricate Caliper Slide Pins
   Remove the caliper slide pins from the bracket (if not already removed with the caliper bolts). Inspect the rubber boots for tears or damage - replace if compromised. Wipe old grease from the slide pins and inspect for corrosion or scoring. Clean the slide pin bores in the caliper bracket. Apply a thin coat of high-temperature synthetic brake grease to the slide pins. Ensure the rubber boots are properly seated when reinstalling pins.
7. 7

   Compress Caliper Pistons
   Using a brake caliper piston compression tool or large C-clamp, slowly and evenly compress the caliper piston(s) back into the caliper bore. Place the tool against the piston and the back of the caliper housing. Apply steady pressure - the piston should move smoothly. If resistance is excessive or piston does not move, verify EPB service mode is still active. Monitor the brake fluid reservoir - fluid level will rise as pistons compress. Remove excess fluid if necessary to prevent overflow. For dual-piston calipers on the EDV 500, compress both pistons evenly.
8. 8

   Install New Brake Pad Hardware
   Install new anti-rattle clips and hardware from the brake pad kit onto the caliper bracket. Ensure clips are fully seated in their grooves and positioned correctly per the instruction sheet included with pads. Apply a small amount of anti-seize compound to the pad backing plate edges where they contact the caliper bracket (avoid getting any compound on the friction material).
9. 9

   Install New Brake Pads
   Install the new inner and outer brake pads into the caliper bracket, ensuring they are properly seated in the hardware clips. Verify correct orientation - the friction material should face the rotor, and any wear sensor connectors should be positioned as noted during removal. Pads should sit flat against the caliper bracket and move slightly within the mounting hardware.
10. 10

    Reinstall Brake Caliper
    Remove the caliper from its supported position. Carefully position the caliper over the new brake pads and rotor, aligning the slide pin bolt holes. Ensure brake pads remain properly seated as caliper is lowered. Thread the upper and lower caliper bolts by hand first to ensure proper thread engagement. Once both bolts are hand-started, torque to manufacturer specification using torque wrench. Note: Torque specifications are not available in database - consult Rivian service manual for proper values (typically 80-100 ft-lbs for caliper slide bolts on vehicles this size, but verify before proceeding).
11. 11

    Repeat for Opposite Side
    Repeat steps 2 through 10 for the opposite front wheel assembly. Ensure both sides receive identical service and all components are properly torqued. Maintain EPB service mode throughout the procedure on both sides.
12. 12

    Reinstall Wheels and Exit Service Mode
    Reinstall both front wheels, threading lug nuts by hand first. Lower vehicle partially so wheels contact ground but vehicle weight is still on jack stands. Torque lug nuts to specification in a star pattern (consult Rivian manual for exact torque value, typically 150 ft-lbs for commercial vehicles). Fully lower vehicle and remove jack stands. Using diagnostic scan tool, exit EPB service mode per scan tool instructions. This will reset the electronic parking brake system.
13. 13

    Perform Brake System Bed-In Procedure
    Check brake fluid level in reservoir and top off with fresh DOT 4 fluid to MAX line if needed. Before driving, pump brake pedal firmly 10-15 times with vehicle in Park to seat the new pads against rotors and restore proper pedal feel. Start vehicle and verify brake warning lights are off and no fault codes are present. Perform initial test stop at low speed (under 5 mph) in a safe area to verify brake function.

Reassembly

1. Torque all caliper bolts to manufacturer specification using proper torque wrench
2. Ensure brake hoses are not twisted, kinked, or under tension after caliper installation
3. Verify all brake hardware is installed and no parts remain unused
4. Double-check that wheels are torqued properly in star pattern
5. Confirm brake fluid reservoir is at proper level with fresh DOT 4 fluid
6. Ensure electronic parking brake system has been properly exited from service mode via scan tool

Verification

• With vehicle running, verify brake pedal is firm and does not sink when steady pressure is applied - if pedal is spongy, air may be in system requiring bleeding
• Check for any brake fluid leaks around calipers, hoses, and master cylinder
• Using diagnostic scan tool, verify no brake system fault codes are present and all systems show ready status
• Test electronic parking brake operation - engage and disengage to verify proper function
• Perform test drive in safe area starting with gentle stops from low speeds, gradually increasing to normal braking from 30-40 mph
• During first 200 miles, avoid hard braking when possible to allow proper pad bedding - expect some initial brake noise or vibration during bed-in period
• Listen for any unusual noises (grinding, squealing beyond normal new pad sound, clicking) that might indicate improper installation
• Verify even braking with no pulling to either side - pulling may indicate caliper issue or contaminated pad on one side
• After 50-100 miles, re-check wheel lug nut torque and verify proper seating
• If brake warning lights illuminate, pedal feel is abnormal, or vehicle pulls during braking, discontinue use immediately and have system inspected by qualified technician

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