Brake Line - Single

Replacement of a single damaged or corroded brake line section on the 2022 Rivian EDV 500, including flaring, fitting, and bleeding the brake system.

Warnings

Tools required

Parts

• Brake line tubing (nickel-copper or stainless steel) × 1 — Match OEM diameter and type, typically 3/16" or 4.75mm
• Brake line fittings (if not reusing) × 2 — Match thread size to vehicle specification
• Brake line mounting clips × 2 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake firmly
2. Disconnect 12V negative battery cable and wait 5 minutes for system capacitors to discharge
3. Using scan tool or driver display, verify electronic parking brake is released (if applicable to work location)
4. Raise vehicle using appropriate lift points per Rivian service manual and support on jack stands rated for vehicle weight
5. Remove wheel(s) corresponding to the brake line being replaced
6. Identify the damaged section of brake line and trace routing from master cylinder or ABS module to caliper/wheel cylinder
7. Place drain pan under work area to catch brake fluid
8. Clean the area around brake line fittings with wire brush and apply penetrating oil to fittings (allow 10-15 minutes to penetrate)

Procedure

1. 1

   Depressurize and drain brake system section
   Carefully open the bleeder valve at the wheel cylinder or caliper corresponding to the damaged line. Allow brake fluid to drain into pan. Do not press brake pedal during this process. If the line is between master cylinder and ABS module, consult service manual for proper depressurization procedure as system may be under residual pressure.
2. 2

   Disconnect damaged brake line
   Using appropriate flare nut wrench (not standard wrench, which will round off fittings), carefully loosen and disconnect both ends of the damaged brake line section. Turn fittings counterclockwise while supporting the mating component with a backup wrench to prevent twisting. If fittings are seized, apply additional penetrating oil and allow more time before attempting removal.
3. 3

   Remove mounting clips and extract line
   Release any mounting clips, brackets, or retainers securing the brake line along its path. Note exact routing, orientation, and clearances from other components, suspension parts, and the high-voltage battery enclosure. Take photos for reference during installation. Remove the damaged line completely.
4. 4

   Measure and cut replacement tubing
   Measure the length needed for the replacement line, accounting for bends and connection points. Add 2-3 inches to allow for flaring and final trimming. Using tubing cutter, make clean, square cuts on the replacement brake line tubing. Deburr inside and outside edges completely to prevent restriction or damaged seals.
5. 5

   Create flares on both ends
   Install fittings onto tubing in correct orientation before flaring (cannot be installed after). Using double-flare tool (ISO flare for metric fittings), create proper flares on both ends of the new line. Follow flaring tool instructions precisely. Inspect flares for cracks, splits, or incomplete formation. Flares must be concentric and smooth with no metal fragments.
6. 6

   Form bends in new line
   Using tube bending tool or bending spring, carefully form bends to match the original line routing. Avoid kinks, sharp bends, or flat spots. Maintain minimum bend radius of 3 times the tube diameter. Ensure line will have adequate clearance from suspension components through full range of motion, steering travel, and does not contact high-voltage battery enclosure or orange HV cables.
7. 7

   Test fit new brake line
   Route the new line along the original path without connecting fittings. Verify clearances at all points, especially near moving components (control arms, axles, steering). Check that line does not interfere with wheel travel at full compression and extension. Adjust bends as necessary before final installation.
8. 8

   Install and connect new brake line
   Install mounting clips and brackets along the line route. Connect fittings at both ends, starting threads by hand to prevent cross-threading. Tighten flare nut fittings with flare nut wrench to manufacturer specification (typically 10-12 ft-lbs for 3/16" line, but verify in service manual as torque specs were not provided in database). Use backup wrench on mating component. Do not overtighten as this can damage flares and cause leaks.
9. 9

   Inspect installation and clearances
   Verify all mounting clips are secure and line is properly supported along entire length. Physically move suspension through travel range and turn steering lock-to-lock to confirm no contact with brake line. Ensure minimum 1/2 inch clearance from all moving parts and heat sources.
10. 10

    Fill brake fluid reservoir
    Fill the master cylinder reservoir with fresh DOT 4 brake fluid to the MAX line. Never reuse old brake fluid. Keep reservoir covered when not actively adding fluid to prevent moisture contamination. Keep brake fluid away from painted surfaces.
11. 11

    Bleed the brake system
    Bleed the brake system starting with the wheel furthest from the master cylinder (typically right rear), then moving to left rear, right front, and left front. If replacing a line to a specific corner, prioritize bleeding that corner thoroughly. For vehicles with ABS/stability control, use scan tool to cycle ABS pump and valves during bleeding process to purge air from modulator. Repeat bleeding sequence until fluid runs clear with no air bubbles at all four corners.
12. 12

    Check for leaks
    With engine off (or vehicle in ready mode for electric systems), have an assistant firmly press brake pedal and hold. Inspect all fittings, flares, and connections along the new brake line for any signs of fluid seepage. Tighten fittings slightly if minor weeping occurs, but do not overtighten. If significant leakage occurs, depressurize system and inspect flares for damage.
13. 13

    Perform brake system function test
    With vehicle still on jack stands, place vehicle in ready mode. Pump brake pedal several times and verify firm pedal feel with no sponginess. Pedal should not sink slowly when held under constant pressure. Check brake fluid level and top off to MAX line if needed. Clear any brake system warning lights using scan tool if they appeared during the repair process.

Reassembly

1. Reinstall wheels and torque lug nuts to Rivian specification (typically 150-160 ft-lbs, verify in owner's manual)
2. Lower vehicle from jack stands carefully
3. Reconnect 12V negative battery cable
4. Top off brake fluid reservoir to MAX line one final time after system has settled

Verification

• Before driving, pump brake pedal 10-15 times with vehicle in park to verify firm pedal feel and normal pedal height
• Check brake fluid level - should be at MAX line with no visible air bubbles in reservoir
• Visually inspect all connections for any signs of fluid leakage around the new brake line
• Perform low-speed brake test (under 5 mph) in a safe area to verify normal braking response before road driving
• During initial test drive, verify normal brake pedal feel, no pulling to one side, no warning lights, and regenerative braking functions normally
• After 50-100 miles, re-inspect all brake line fittings for any signs of seepage or loosening, and recheck brake fluid level
• If brake pedal feels soft, warning lights appear, or braking performance is abnormal in any way, do not drive vehicle and have it towed to a qualified service facility immediately

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