Brake Hose - Rear

Replacement of the rear brake hose on a 2022 Rivian EDV 500, requiring brake system bleeding and safety-critical torque verification.

Warnings

Tools required

Parts

• Rear brake hose assembly × 1 — Use OEM Rivian specification
• Brake hose mounting clips/brackets × 1 — Inspect and replace if damaged
• Copper crush washers for banjo bolts × 4 — Use OEM specification - typically 2 per connection
• DOT 4 brake fluid × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks in front of front wheels
3. Open hood and locate 12V battery in front compartment
4. Disconnect 12V battery negative terminal and wait 2 minutes for system discharge
5. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
6. Raise rear of vehicle using floor jack at designated rear jacking point
7. Install jack stands at reinforced frame mounting points per owner's manual
8. Lower vehicle onto jack stands and verify stability
9. Remove rear wheel on side requiring brake hose replacement
10. Clean work area around brake caliper and hose connections with wire brush
11. Locate brake fluid reservoir under hood and check fluid level
12. Use fluid extraction pump or turkey baster to remove approximately half the fluid from reservoir to prevent overflow during caliper work

Procedure

1. 1

   Position drain pan and prepare work area
   Position drain pan under rear brake caliper assembly. Spray penetrating oil on banjo bolt at caliper and brake line fitting at chassis bracket. Allow to soak for 5 minutes. Identify the brake hose routing from caliper to frame-mounted hard line.
2. 2

   Remove banjo bolt at caliper
   Using a flare nut wrench on the banjo bolt at the brake caliper, carefully loosen and remove the bolt while holding the caliper steady. Note the position of copper crush washers on both sides of the banjo fitting - there should be one washer between the hose fitting and caliper, and one between the bolt head and fitting. Allow brake fluid to drain into pan. Cap or plug the caliper port immediately with a clean rubber cap to minimize fluid loss and prevent contamination.
   ⚠Brake fluid will begin flowing immediately upon loosening. Have drain pan positioned and be prepared for fluid loss.
3. 3

   Disconnect brake hose from chassis hard line
   Locate where the flexible brake hose connects to the rigid brake line at the chassis mounting point. Using the appropriate flare nut wrench (typically 10mm or 12mm), carefully loosen the threaded fitting. Use a backup wrench on the hose end fitting to prevent twisting the hose. Once loose, unthread completely by hand and allow remaining fluid to drain into pan.
4. 4

   Remove brake hose mounting bracket
   Locate the intermediate mounting bracket(s) that secure the brake hose to the suspension or chassis. Remove any clips, bolts, or retaining hardware securing the hose in these brackets. Note the routing path and position of any spacers or grommets for reinstallation.
5. 5

   Remove old brake hose assembly
   With all connections and brackets released, carefully remove the old brake hose assembly. Inspect the mounting brackets and clips for damage, corrosion, or excessive wear. Replace any damaged hardware. Clean mounting surfaces with wire brush.
6. 6

   Prepare new brake hose for installation
   Unpack new OEM brake hose assembly and verify correct part number and routing configuration. Install NEW copper crush washers on the banjo bolt - place one washer on each side of the banjo fitting eyelet. Do not reuse old washers. Remove any protective caps or plugs from hose ends just before installation.
7. 7

   Route new brake hose
   Route the new brake hose along the same path as the original, ensuring it follows the proper clearance from suspension components, steering linkage, and wheel travel zones. Install the hose into any intermediate mounting brackets or clips, but do not fully tighten bracket hardware yet. Verify the hose has adequate slack for full suspension travel and steering movement without stretching or kinking.
8. 8

   Connect brake hose to chassis hard line
   Thread the brake hose fitting into the chassis-mounted hard line connection by hand to start the threads. Ensure threads engage smoothly without cross-threading. Once hand-tight, use flare nut wrench to tighten the fitting while using backup wrench on hose end. Tighten to manufacturer specification (typically 11-13 ft-lbs for brake line fittings, but verify with service manual as no torque specs were provided in database). Do not overtighten as this can damage flare seat.
   ⚠Cross-threading brake line fittings will cause dangerous leaks. If fitting does not thread smoothly by hand, remove and inspect threads.
9. 9

   Install banjo bolt at caliper
   Remove protective cap from caliper port. Position the banjo fitting with new copper crush washers (one on each side) at the caliper inlet. Insert banjo bolt and thread by hand until snug. Using torque wrench, tighten banjo bolt to manufacturer specification (typically 18-22 ft-lbs for brake system banjo bolts, but verify with service manual as specific torque was not provided in database). Ensure fitting does not rotate during tightening.
10. 10

    Secure mounting brackets
    With both ends of brake hose connected, verify hose routing once more for clearance through full suspension travel. Secure all intermediate mounting brackets and clips. Ensure hose is not twisted and maintains natural curve without stress points.
11. 11

    Refill brake fluid reservoir
    Return to brake fluid reservoir under hood. Fill reservoir to MAX line with fresh DOT 4 brake fluid meeting Rivian specifications. Keep reservoir topped off throughout bleeding process.
12. 12

    Bleed rear brake circuit
    Attach brake bleeding kit to bleeder valve on rear caliper where hose was replaced. If using manual bleeding method, have assistant pump brake pedal 3-5 times and hold pressure. Open bleeder valve and observe fluid flow into clear tube. Close valve before pedal reaches floor. Repeat until fluid runs clear without air bubbles. If using pressure bleeder, follow manufacturer instructions. Monitor reservoir level constantly and refill as needed.
    ⚠️Never allow brake fluid reservoir to empty during bleeding. This will introduce air into ABS module requiring dealer-level service.
13. 13

    Bleed remaining brake circuits
    Bleed all four brake calipers in proper sequence (typically right rear, left rear, right front, left front for this vehicle configuration). This ensures complete air removal from system. Continue each wheel until fluid runs clear without bubbles. Top off reservoir to MAX line when complete.
14. 14

    Reinstall wheel and lower vehicle
    Reinstall rear wheel and hand-tighten lug nuts in star pattern. Raise vehicle slightly off jack stands using floor jack. Remove jack stands and carefully lower vehicle to ground. Torque wheel lug nuts to specification (typically 130-140 ft-lbs for Rivian EDV, but verify in owner's manual) in star pattern.
15. 15

    Reconnect battery and reset brake system
    Reconnect 12V battery negative terminal. If available, use Rivian-compatible scan tool to clear any brake system fault codes and verify ABS module communication. Start vehicle and verify brake warning lights extinguish after system check.

Reassembly

1. Verify all brake line connections are tight and free from leaks
2. Confirm brake fluid reservoir is at MAX line with proper DOT 4 fluid
3. Ensure wheel lug nuts are torqued to specification in star pattern
4. Double-check that no tools or parts were left in wheel well area

Verification

• Before moving vehicle, pump brake pedal multiple times - pedal should become firm and hold pressure without sinking
• Inspect all brake hose connections for leaks while assistant applies firm brake pedal pressure
• Check brake hose routing with steering at full lock both directions and suspension at full compression/extension to verify no interference
• Test drive in safe area at low speed (under 15 mph) to verify brake function before normal operation
• Perform several moderate brake applications from 25-30 mph in safe area to verify proper braking
• Re-inspect all connections for leaks after test drive
• Check brake fluid level after test drive and top off if needed
• Verify brake pedal feel is firm and similar to pre-repair condition - if pedal is soft or spongy, additional bleeding is required
• If brake warning light remains illuminated or pedal feel is abnormal, do not drive vehicle - have it towed to qualified service facility

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