Brake Lines - Complete Set

Complete replacement of all brake lines on the 2023 Rivian EDV 500, including removal of damaged or corroded lines and installation of new brake line set with proper routing and bleeding.

Warnings

Tools required

Parts

• Complete brake line set for Rivian EDV 500 × 1 — Use OEM specification
• Brake line mounting clips × 1 — Use OEM specification
• Brake line retaining brackets × 1 — As needed per vehicle condition
• Copper crush washers for brake line fittings × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 2 qt

Preparation

1. Park vehicle on level concrete surface in well-ventilated area away from ignition sources
2. Place wheel chocks behind and in front of all wheels before lifting
3. Disable low voltage system by disconnecting 12V battery negative terminal and waiting 2 minutes for system capacitors to discharge
4. Engage parking brake and place transmission in Park
5. Using hydraulic jack, raise front of vehicle and secure with jack stands under designated lift points
6. Raise rear of vehicle and secure with jack stands under designated lift points
7. Remove all four wheels and set aside safely
8. Place drain pans under brake master cylinder and at each brake caliper location
9. Document routing of existing brake lines with photographs from multiple angles for reference
10. Clean brake line fittings and surrounding areas with wire brush and penetrating oil, allow to soak 15 minutes
11. Verify replacement brake line kit is complete and matches original routing configuration

Procedure

1. 1

   Drain and isolate brake fluid system
   Using a turkey baster or fluid evacuation tool, remove as much brake fluid as possible from the master cylinder reservoir. Place line clamps or locking vise grips on each flexible brake hose near the calipers to minimize fluid loss during line removal. Cap or plug the master cylinder reservoir to prevent debris entry.
2. 2

   Disconnect lines at master cylinder
   Using appropriately sized flare nut wrenches, carefully loosen the brake line fittings at the master cylinder. Work slowly to avoid rounding the fittings. Once loosened, unthread by hand and immediately cap the master cylinder ports with clean plugs. Allow fluid to drain into catch container.
3. 3

   Remove brake lines from ABS module connections
   Locate the ABS/ESC module and electronic brake control module in the engine bay. Using flare nut wrenches, disconnect brake lines from the module outlets. Note the orientation and position of each line connection. Cap all open ports immediately to prevent contamination. On EDV models, the brake module is integrated with regenerative braking controls; avoid disturbing electrical connections.
4. 4

   Remove front brake line routing clips and brackets
   Working from master cylinder toward front wheels, remove all mounting clips, brackets, and fasteners securing brake lines to chassis and suspension components. Document each mounting location. Remove lines carefully to avoid damage to surrounding components including wiring harnesses and coolant lines for electric drive units.
5. 5

   Disconnect front brake lines at flexible hoses
   At each front wheel, use flare nut wrenches to disconnect the hard brake lines from the flexible brake hoses at the frame mounting point. Hold the hose fitting stationary while loosening the line nut to prevent twisting the hose. Cap all open ends immediately.
6. 6

   Remove rear brake line routing and hardware
   Trace rear brake lines from ABS module along frame rails to rear axle. Remove all clips, brackets, and fasteners. On EDV models, brake lines route near battery pack underbody protection; work carefully to avoid damage to battery enclosure. Remove lines from chassis routing channels.
7. 7

   Disconnect rear brake lines at flexible hoses
   At each rear wheel, disconnect hard brake lines from flexible hoses using flare nut wrenches. Hold hose fittings to prevent twisting. Remove old brake lines completely from vehicle and set aside for reference during installation.
8. 8

   Prepare and route new master cylinder to ABS module lines
   Begin installation with lines connecting master cylinder to ABS/brake control module. Compare new lines to old for proper bend configuration and length. If bending is required, use proper brake line bending tool to avoid kinking. Route lines through chassis channels, ensuring adequate clearance from heat sources, moving suspension components, and sharp edges. Install mounting clips finger-tight initially.
9. 9

   Install new front brake lines
   Route new brake lines from ABS module to front wheel connection points, following original path documented in photographs. Ensure lines maintain proper clearance from steering components, CV axles, and electric motor assemblies. Install new mounting brackets and clips in original locations. Leave all fittings hand-tight until routing is confirmed.
10. 10

    Install new rear brake lines
    Route new rear brake lines from ABS module along frame rails to rear connection points. On EDV models, ensure lines are secured in protective channels and maintain clearance from battery pack and rear drive unit. Verify adequate clearance during suspension articulation. Install mounting hardware hand-tight.
11. 11

    Verify routing and secure all connections
    Inspect entire brake line installation for proper routing, adequate clearance, and correct mounting. Ensure no lines contact suspension, steering, driveline, or sharp edges. Verify lines have proper support every 12-18 inches. Check that lines are not twisted or kinked. Tighten all mounting brackets and clips securely. Beginning at master cylinder, tighten all flare nut fittings using flare nut wrenches to manufacturer specifications (typically 11-13 ft-lbs for 3/16 inch lines, 13-15 ft-lbs for 1/4 inch lines, but verify with OEM specifications as torque specs are not available in database).
12. 12

    Remove line clamps and connect flexible hoses
    Remove vise grips or line clamps from flexible brake hoses. Inspect flexible hoses for damage; replace if cracking, swelling, or damage is present. Thread hard lines into flexible hose fittings and tighten with flare nut wrenches. Ensure hoses are not twisted and have proper clearance during steering and suspension travel.
13. 13

    Fill brake fluid reservoir and prepare for bleeding
    Remove cap from master cylinder reservoir and fill with fresh DOT 4 brake fluid to MAX line. Keep reservoir filled throughout bleeding process. Connect pressure bleeder if available, or prepare for manual bleeding procedure with assistant. For Rivian EDV models, verify whether scan tool activation of ABS module is required for complete bleeding.
14. 14

    Bleed brake system at all four corners
    Bleed brakes in proper sequence (typically RR, LR, RF, LF for most vehicles, but verify EDV-specific sequence). At each wheel, attach clear hose to bleeder screw into catch container. Open bleeder and allow fluid to flow until clear, bubble-free fluid emerges. Close bleeder before pressure is released. Repeat at each wheel. Maintain reservoir level above MIN at all times. For electronic brake systems, perform multiple bleeding cycles and verify pedal feel between cycles.
15. 15

    Perform final system bleed and ABS module purge
    After initial bleeding, perform secondary bleeding sequence to purge ABS module. This may require scan tool with Rivian-specific software to cycle ABS valves during bleeding. If scan tool is not available, perform aggressive pedal bleeding with at least 10 full strokes per wheel while monitoring for firm pedal feel. Top off reservoir to MAX line when complete.

Reassembly

1. Reinstall all four wheels and torque lug nuts to manufacturer specification in star pattern
2. Remove jack stands and carefully lower vehicle to ground
3. Reconnect 12V battery negative terminal
4. Start vehicle and verify brake warning lights extinguish after system pressurization
5. Check all brake line connections for leaks with engine running and brake pedal applied
6. Inspect master cylinder reservoir level and top off if needed with DOT 4 fluid

Verification

• With engine running, pump brake pedal several times and verify firm, consistent pedal feel with no excessive travel
• Perform static brake test: with vehicle stationary and parking brake released, apply firm brake pedal pressure and verify no pedal fade or sinking over 30 seconds
• Visually inspect all brake line connections, fittings, and flex points for fluid leaks
• Perform low-speed test drive in safe area: verify proper brake function, no pulling, and firm pedal at speeds up to 15 mph before proceeding
• After low-speed verification, perform controlled stops from 25 mph in safe area to verify proper brake force and ABS function
• Check for brake system warning lights or fault codes using scan tool; address any codes before returning vehicle to service
• Verify regenerative braking is functioning properly (regeneration should be felt during gentle deceleration)
• Re-inspect all connections after test drive for any signs of fluid seepage
• Document brake fluid level and verify proper operation of brake fluid level sensor
• CRITICAL: Advise vehicle owner that brake pedal feel may change during first 100 miles as system fully purges residual air; if pedal feel degrades or warning lights appear, discontinue use immediately and re-bleed system

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