This procedure covers removal and replacement of the third brake light (center high-mounted stop lamp) on the 2023 Rivian EDV 500 commercial electric delivery van.

Warnings

Tools required

Parts

• Third brake light assembly × 1 — Use OEM specification
• Interior headliner trim clips × 5 — Replace any damaged clips
• Roof seal gasket × 1 — Use OEM specification if damaged

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle completely and remove key fob from interior
3. Open rear cargo doors fully and secure them in open position
4. Allow vehicle to sit for 5 minutes to ensure all systems are fully powered down
5. If working outdoors, ensure vehicle is not in direct sunlight as roof panels can become very hot
6. Gather all tools and new parts - verify the replacement third brake light matches OEM specifications
7. Document current wire routing and connector orientation with photos for reference during reassembly

Procedure

1. 1

   Access interior cargo area headliner
   Enter the cargo area from the rear doors. Locate the headliner panel directly below where the third brake light is mounted externally on the roof. This will be at the front of the cargo area, near the bulkhead separating cargo from cab.
2. 2

   Remove headliner access panel
   Using the trim clip removal tool, carefully pry down the headliner access panel. Start at one corner and work around the perimeter. There are typically 4-6 push clips securing this panel. Remove the panel slowly to avoid breaking clips or damaging headliner material. Set aside panel and clips.
3. 3

   Disconnect third brake light electrical connector
   Locate the electrical connector leading to the third brake light assembly. It will be a 2-pin or 3-pin connector depending on whether unit has standard or enhanced LED functionality. Press the locking tab and carefully disconnect the connector. Use electrical connector release tool if needed. Note the connector orientation with tape or photo.
4. 4

   Access exterior mounting points
   From outside the vehicle, position yourself to safely access the roof. The third brake light on the EDV 500 is typically mounted on the roof above the cargo area. Clean any dirt or debris around the light assembly with a clean cloth to prevent contamination when opening.
5. 5

   Remove exterior lens cover if applicable
   Some EDV 500 third brake lights have a removable lens cover secured by small clips or fasteners. If present, carefully release these clips using a trim tool. If the assembly is sealed, skip this step and proceed to remove entire assembly.
6. 6

   Remove third brake light mounting fasteners
   Using the T20 or T25 Torx driver (verify which size fits your specific fasteners), remove the mounting screws securing the brake light assembly to the roof. There are typically 2-4 mounting screws. Keep fasteners organized as they may have sealing washers that must be reused.
7. 7

   Extract third brake light assembly
   Carefully lift the brake light assembly from its mounting position. The wiring harness will still be connected from the interior side. Gently pull enough slack to bring the assembly and wiring through the roof opening. Work slowly to avoid damaging the roof gasket seal or painted surfaces.
8. 8

   Inspect mounting area and gasket
   Examine the roof opening for any signs of water intrusion, corrosion, or damage. Inspect the rubber gasket seal - if it is cracked, compressed, or damaged, it must be replaced to prevent water leaks. Clean the mounting surface thoroughly with a clean cloth.
9. 9

   Prepare new third brake light assembly
   Remove new third brake light from packaging. Verify it matches the original part exactly. Ensure any gasket or seal is properly positioned on the new assembly. If gasket is separate, install it on the assembly before installation, ensuring proper alignment in the gasket groove.
10. 10

    Route wiring through roof opening
    From the exterior, feed the new third brake light wiring harness down through the roof opening into the cargo area. Leave sufficient slack but avoid excess wire that could interfere with headliner reinstallation. From inside, guide the connector to the mating connector location.
11. 11

    Position and secure new assembly
    Align the new third brake light assembly to the roof mounting holes. Ensure the gasket seats properly against the roof surface all around the perimeter. Start all mounting screws by hand before tightening any. Tighten screws in a cross pattern to ensure even gasket compression. Do not overtighten as this can damage the gasket or assembly housing.
12. 12

    Connect electrical connector
    From inside the cargo area, align and connect the electrical connector to the third brake light wiring harness. Push firmly until you hear or feel a positive click indicating the locking tab is engaged. Gently tug on the connection to verify it is secure.
13. 13

    Test third brake light operation
    Have an assistant sit in the driver seat and turn on the vehicle ignition (do not need to put in drive mode). Press and hold the brake pedal while you observe the third brake light from the rear. Verify the light illuminates fully and with proper brightness. If using a multimeter, verify voltage at the connector matches specifications (typically 12-14V when active).
14. 14

    Reinstall headliner access panel
    Route any excess wiring neatly above the headliner panel location. Align the headliner access panel to its original position. Press firmly on each clip location to re-seat the push clips. Ensure panel is flush with surrounding headliner and all clips are fully engaged.

Reassembly

1. Verify all trim clips are properly seated and headliner panel is flush with no gaps
2. Ensure no tools or parts were left in the cargo area or on the roof
3. Check exterior mounting area for proper gasket seal with no gaps or raised edges
4. Verify wiring is properly routed and not pinched between panels or sharp edges

Verification

• Turn vehicle ignition on and depress brake pedal - verify third brake light illuminates brightly and consistently
• Have someone observe from 50+ feet behind the vehicle in daylight to confirm adequate brightness
• Test in low-light conditions to verify proper LED function and no flickering
• Check for proper function during multiple brake applications - light should respond instantly each time
• Inspect roof mounting area for any signs of water leaks after next rain or vehicle wash
• Verify all cargo area headliner panels are secure with no rattles or loose sections
• Perform a test drive with brake applications to ensure light functions properly under real-world conditions
• Document repair with photo of illuminated brake light for vehicle maintenance records

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