Brake Line - Single

This procedure covers the replacement of a single damaged or corroded brake line on a 2023 Rivian EDV 500, including bleeding the brake system afterward.

Warnings

Tools required

Parts

• Brake line section (pre-fabricated to match routing or bulk brake line tubing) × 1 — Use OEM specification or NiCopp/Cunifer brake line material
• Brake line fittings (if fabricating) × 2 — Match thread size to vehicle specifications
• Brake line mounting clips × 2 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and place wheel chocks behind wheels that will remain on the ground
2. Ensure vehicle is in Park with parking brake disengaged (you may need to release parking brake if replacing rear brake lines)
3. Identify which brake line needs replacement by inspecting for leaks, corrosion, or damage
4. If replacing a rear brake line and parking brake is electric, ensure it is released via vehicle controls
5. Lift vehicle at appropriate jacking points and secure on jack stands rated for vehicle weight (approximately 6,000 lbs)
6. Remove wheel(s) on the side where brake line work will be performed
7. Have a fire extinguisher nearby as a general safety precaution when working on vehicles
8. Put on safety glasses and nitrile gloves before handling brake fluid

Procedure

1. 1

   Prepare brake fluid reservoir
   Open the hood and locate the brake fluid reservoir. Use a turkey baster or fluid transfer pump to remove brake fluid from the reservoir until it is at the minimum fill line. This prevents overflow when you open the brake lines. Place removed fluid in a suitable waste container for proper disposal.
2. 2

   Apply penetrating oil to fittings
   Spray penetrating oil on both brake line fittings where the damaged line connects. Allow it to soak for 5-10 minutes to ease removal. Clean the fittings with a wire brush to remove any surface corrosion or debris.
3. 3

   Position catch container and disconnect brake line
   Place a catch container under the brake line connection point. Using the appropriate size flare wrench (not a standard wrench, as it will round the fittings), carefully loosen and disconnect the brake line at both connection points. Expect brake fluid to drip from the line and connections. Cap or plug the open ports immediately with rubber caps or clean shop rags to minimize fluid loss and contamination.
4. 4

   Remove mounting clips and old brake line
   Trace the brake line along its routing path and remove all mounting clips or brackets securing it to the chassis, suspension, or body. Take photos or make notes of the exact routing path, clip locations, and any protective grommets or sleeves. Remove the old brake line completely from the vehicle.
5. 5

   Measure and prepare replacement brake line
   If using pre-fabricated brake line, verify it matches the old line's length and fitting configuration. If fabricating from bulk tubing, measure the old line carefully and add 6-12 inches for bending allowance. Cut the new brake line to length using a tubing cutter for a clean, square cut. Deburr the cut ends thoroughly.
6. 6

   Flare brake line ends
   If fabricating, install the brake line fittings (nuts) onto the tubing BEFORE flaring. Using a double flaring tool, create double flares on both ends of the brake line according to the tool manufacturer's instructions. Inspect flares carefully for cracks, irregularities, or incomplete formation. Flares must be perfectly formed to prevent leaks.
7. 7

   Bend and shape brake line
   Using a brake line bending tool or carefully bending by hand (avoid kinking), shape the new brake line to match the routing of the original line. Ensure the line follows the same path, maintains proper clearance from moving suspension components, exhaust, wheels, and sharp edges. Test fit the line before final installation.
8. 8

   Install new brake line
   Route the new brake line along the correct path, ensuring it matches the original routing. Install all mounting clips and brackets in their original positions to secure the line. Verify the line has adequate clearance from all moving parts, heat sources, and sharp edges. The line should not be stretched tight or have excessive slack.
9. 9

   Connect brake line fittings
   Remove the caps or plugs from the brake line connection points. Thread the fittings by hand first to ensure proper thread engagement and prevent cross-threading. Once hand-tight, use the flare wrench to snug the fittings. Without manufacturer torque specifications, tighten firmly but do not overtorque—typically 10-15 ft-lbs for brake line fittings, though this should be verified with a professional or Rivian service manual.
10. 10

    Refill brake fluid reservoir
    Fill the brake fluid reservoir to the MAX line with fresh DOT 4 brake fluid from a sealed container. Keep the reservoir topped off throughout the bleeding process.
11. 11

    Bleed the brake system
    Bleed the brake system starting with the wheel furthest from the master cylinder (typically right rear), then left rear, right front, and left front. At each wheel, attach clear tubing to the bleeder valve with the other end submerged in fresh brake fluid in a container. Have an assistant press the brake pedal slowly and hold, then open the bleeder valve to release fluid and air. Close the valve before the pedal reaches the floor. Repeat until no air bubbles appear in the tubing. Check and refill the reservoir frequently during bleeding.
12. 12

    Inspect for leaks
    With the brake system bled, have an assistant firmly press the brake pedal and hold pressure for 30 seconds. Carefully inspect all connections on the new brake line for any signs of fluid seepage or leaks. Wipe connections dry and repeat the pressure test. If any leaks are found, release pressure and re-tighten the affected fitting slightly.
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the wheel(s) that were removed and tighten lug nuts in a star pattern. Lower the vehicle from the jack stands. Once the vehicle is on the ground, perform final torque on lug nuts according to Rivian specifications (typically 160 ft-lbs for this vehicle, but verify with owner's manual).

Reassembly

1. Ensure brake fluid reservoir is filled to the MAX line with fresh DOT 4 brake fluid
2. Verify all mounting clips are installed and brake line is properly secured along its entire length
3. Double-check that brake line has adequate clearance from suspension components, exhaust, and wheels throughout their full range of motion
4. Dispose of old brake fluid and brake line according to local environmental regulations

Verification

• With the vehicle still elevated or on the ground, pump the brake pedal several times. The pedal should become firm and hold pressure without slowly sinking to the floor
• Perform a static brake pedal test: press and hold firm brake pedal pressure for 60 seconds. The pedal should not sink or feel spongy. If it does, air remains in the system or there is a leak
• Start the vehicle and verify brake system warning lights do not illuminate on the dashboard
• Perform a low-speed test drive in a safe area (empty parking lot). Test brakes at 5-10 mph to verify normal braking function and straight-line stops without pulling to one side
• After test drive, re-inspect all connections on the new brake line for any signs of leakage or seepage
• Verify brake pedal feel is firm and consistent with pre-repair operation
• Check brake fluid reservoir level again and top off if necessary. Mark date of fluid service for maintenance records
• If brake pedal feels soft, spongy, or travels too far, or if any leaks are present, DO NOT DRIVE THE VEHICLE. Re-bleed the system or seek professional service immediately

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