Brake Lines - Complete Set

Complete replacement of all brake lines on the 2022 Rivian EDV 500, including removal of old lines, installation of new lines, and complete brake system bleeding.

Warnings

Tools required

Parts

• Complete brake line set (pre-bent OEM or universal kit) × 1 — Use OEM specification or vehicle-specific brake line kit
• Brake line clips and retainers × 1 — OEM brake line mounting hardware
• Brake line fitting seals/washers × 8 — Copper or composite sealing washers
• Brake bleeder screws (if corroded) × 4 — M8 or M10 bleeder screws as needed

Fluids

• DOT 4 Brake Fluid — 2 qt

Preparation

1. Park vehicle on level, solid ground and place wheel chocks behind rear wheels
2. Disable the high-voltage system using Rivian service mode if available, or ensure vehicle has been off for at least 15 minutes
3. Apply penetrating oil to all brake line fittings at master cylinder, ABS module, proportioning valves, and all four calipers. Allow to soak minimum 30 minutes, ideally overnight
4. Raise vehicle and support securely on four jack stands at manufacturer-specified lift points
5. Remove all four wheels and set aside
6. Take detailed photographs of brake line routing from multiple angles, noting all mounting clips and brackets
7. Place catch pans under work areas to collect brake fluid
8. Connect Rivian diagnostic tool or compatible scan tool to vehicle OBDII port and verify communication with brake control module
9. Open brake fluid reservoir and use turkey baster or syringe to remove as much old fluid as possible to minimize spillage

Procedure

1. 1

   Disconnect battery and verify HV system safe state
   Disconnect the 12V auxiliary battery negative terminal. Verify that all high-voltage indicators are off and the vehicle has been de-energized for at least 15 minutes. Confirm you can identify all orange high-voltage cables and will maintain clearance throughout the procedure.
2. 2

   Remove brake lines from calipers
   Starting at the right front caliper, use a flare nut wrench to carefully loosen the brake line fitting at the caliper. Have a catch pan ready as fluid will drain. Once loose, unscrew by hand and allow to drain completely. Cap or plug the caliper port immediately. Repeat for left front, right rear, and left rear calipers. Note the orientation and any banjo bolt configurations.
3. 3

   Disconnect brake lines from ABS module and master cylinder
   Locate the ABS/stability control module (typically in engine compartment or under vehicle near front subframe). Use flare nut wrenches to disconnect all brake lines from the ABS module outlets. Work carefully as these fittings are aluminum and easily damaged. Label each line with tape indicating its position (RF, LF, RR, LR). Then disconnect the lines from the master cylinder or brake booster assembly.
4. 4

   Remove brake line mounting hardware
   Working from front to rear, remove all brake line clips, brackets, and retainers securing the lines to the chassis, suspension components, and body. Use a wire brush to clean mounting locations and inspect for rust or damage. Replace any corroded mounting hardware. Keep all hardware organized by location.
5. 5

   Remove old brake lines completely
   Carefully extract all old brake lines from the vehicle, noting their routing paths. If lines pass through grommets in the body or frame, ensure grommets are intact and reusable. Inspect all routing paths for sharp edges, heat sources, or potential pinch points that could damage new lines.
6. 6

   Prepare and fit new brake lines
   If using pre-bent lines, verify each line matches the original routing by comparing to removed lines and reference photos. If fabricating lines, measure carefully and create bends using a proper brake line bending tool to avoid kinking. Ensure all flare fittings are properly formed and inspect for cracks or deformities. Test-fit each line before final installation.
7. 7

   Install brake lines to master cylinder and ABS module
   Begin installation at the master cylinder or brake booster. Install new sealing washers where applicable. Thread fittings by hand first to ensure proper engagement and prevent cross-threading. Once hand-tight, use flare nut wrench to tighten securely. Connect lines to ABS module outlets, ensuring each line goes to the correct port (reference photos and labels). Do not over-tighten aluminum fittings.
8. 8

   Route and secure brake lines along chassis
   Route each brake line according to factory routing path, ensuring lines follow original path away from heat sources, moving suspension components, and sharp edges. Maintain at least 6 inches clearance from any orange high-voltage cables. Install all mounting clips and brackets, ensuring lines are secure but not over-compressed or stressed at bends.
9. 9

   Connect brake lines to calipers
   At each caliper, remove the temporary plug or cap. Install new sealing washers if using banjo fittings. Thread brake line fitting into caliper by hand, ensuring straight engagement. Use flare nut wrench to tighten securely. Verify no cross-threading has occurred and fitting is snug. Repeat for all four calipers.
10. 10

    Inspect all connections and routing
    Perform a complete visual inspection of all brake line connections at the master cylinder, ABS module, and all four calipers. Verify all fittings are properly tightened. Check that all mounting clips are secure and lines have no kinks, twists, or contact with moving parts. Ensure proper clearance from high-voltage components, exhaust, and suspension travel paths.
11. 11

    Fill brake fluid reservoir
    Fill the brake fluid reservoir with fresh DOT 4 brake fluid to the MAX line. Keep the reservoir covered when not actively filling to prevent contamination. Have additional brake fluid readily available for the bleeding process.
12. 12

    Perform initial manual brake bleeding
    Beginning with the wheel farthest from the master cylinder (typically right rear), attach bleeder hose to caliper bleeder screw and submerge end in catch bottle with clean brake fluid. Have assistant slowly depress brake pedal while you open bleeder screw 1/4 turn. Close bleeder before pedal reaches floor. Repeat until fluid flows without air bubbles. Move to left rear, right front, then left front. Check and refill reservoir frequently to prevent air ingestion.
13. 13

    Perform ABS module bleeding procedure
    Using the Rivian diagnostic tool or compatible scan tool, initiate the ABS bleeding procedure. This cycles the ABS pump and valves to purge air from the module. Follow the scan tool prompts exactly. This typically requires repeated manual bleeding cycles at each wheel while the scan tool commands valve operations. Monitor reservoir level constantly and refill as needed.
14. 14

    Final brake system bleeding and pedal feel check
    Perform a final manual bleeding sequence at all four wheels. With engine/vehicle in RUN mode (do not drive), pump brake pedal 30-40 times and verify pedal becomes firm and does not sink. If pedal remains soft or sinks, repeat bleeding process. The pedal should feel firm within the first third of travel. Check all fittings for leaks while assistant applies firm pedal pressure.
15. 15

    Install wheels and perform final torque check
    Reinstall all four wheels and torque lug nuts to Rivian specification (verify in owner's manual, typically 130-150 ft-lbs for EDV). Lower vehicle from jack stands. With vehicle on ground, perform final torque check of all accessible brake line fittings. Wipe down all brake lines and fittings to enable leak detection.

Reassembly

1. Reconnect the 12V auxiliary battery negative terminal
2. Fill brake fluid reservoir to MAX line with fresh DOT 4 fluid and install cap securely
3. Clear any diagnostic trouble codes using scan tool if brake system warnings appeared during service
4. Verify all tools and hardware have been removed from under vehicle and engine compartment

Verification

• With vehicle in PARK and on level ground, start vehicle and verify no brake warning lights are illuminated on dash
• Press brake pedal firmly and hold for 30 seconds - pedal should remain firm with no sinking or unusual softness
• Perform a careful inspection under the vehicle for any signs of brake fluid leakage at all connections. Look for wet spots or drips at master cylinder, ABS module, line fittings, and calipers
• Perform a low-speed test drive (under 10 mph) in a safe, traffic-free area. Verify brake pedal feels normal and vehicle stops straight without pulling
• Gradually increase speed to 25 mph and perform several moderate stops, verifying proper brake function and pedal feel
• Check brake fluid level after test drive and top off if needed
• Re-inspect all brake line connections after test drive for any signs of seeping or leakage
• Test regenerative braking function by verifying vehicle slows when lifting accelerator pedal
• Perform ABS function test if scan tool allows, or verify ABS activates properly during emergency stop on loose surface
• CRITICAL: Inform vehicle operator that brake pedal feel may continue to improve over the first 100-200 miles as system fully seats, but any loss of pedal firmness requires immediate re-inspection

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