Brake Line - Single

Replace a single damaged or corroded brake line on the 2024 Rivian EDV 500, maintaining brake system integrity and safety.

Warnings

Tools required

Parts

• Pre-fabricated brake line (specify length and end fittings) × 1 — Use OEM specification or DOT-approved equivalent
• Brake line mounting clips × 2 — As needed for routing
• Copper crush washers (if banjo fittings used) × 2 — Match fitting size

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Ensure vehicle is on level ground and powered completely off with charge port locked
2. Apply parking brake and place wheel chocks behind wheels that will remain on ground
3. Put on safety glasses and nitrile gloves
4. Identify which brake line needs replacement by inspecting for damage, corrosion, or leaks
5. Take photos of the routing path and mounting clip locations before removal
6. If replacing a line to a wheel, loosen wheel lug nuts before lifting vehicle
7. Lift vehicle using floor jack at appropriate jacking points per owner's manual and secure with rated jack stands
8. Remove wheel if accessing a line running to a caliper
9. Place brake fluid catch container under work area

Procedure

1. 1

   Clean brake line fittings
   Spray both fittings of the damaged brake line with penetrating oil and allow to soak for 10 minutes. Use a wire brush to clean corrosion and debris from the fitting hex surfaces. This prevents rounding off the fittings during removal.
2. 2

   Remove damaged brake line
   Using the appropriate size flare wrench, carefully loosen the brake line fitting at the upstream connection (closest to master cylinder or ABS module). Hold the brake line body or component with a backup wrench to prevent twisting. Expect brake fluid to drain; guide it into your catch container. Repeat for the downstream connection. Remove any mounting clips securing the line to the chassis or suspension components.
3. 3

   Measure and prepare replacement line
   If fabricating a custom line, measure the old line carefully including all bends. Add 2 inches to the straight-line measurement to account for bends. If using a pre-fabricated OEM replacement, verify it matches the routing and fitting types. Ensure replacement line is nickel-copper or stainless steel DOT-approved brake line tubing.
4. 4

   Fabricate line flares if necessary
   If creating a custom line, cut the tubing to length using a tubing cutter for a clean, square edge. Deburr the inside and outside edges. Create double flares on both ends using the double flaring tool according to the tool manufacturer's instructions. Inspect flares for cracks or irregularities; any defects require remaking the flare.
5. 5

   Form bends in replacement line
   Using the brake line bending tool, carefully form bends to match the original routing path. Make gradual bends with a minimum radius of 3 times the line diameter to prevent kinking or collapsing. Test fit the line before final installation to ensure proper routing without tension or interference with suspension components, steering, or driveshafts.
6. 6

   Install replacement brake line
   Route the new brake line following the original path captured in your reference photos. Start by threading the upstream fitting (toward master cylinder) hand-tight, then the downstream fitting. Verify there is no twisting or tension in the line. Install mounting clips in their original locations to secure the line to the chassis. The line should not contact any moving parts or sharp edges.
7. 7

   Torque brake line fittings
   Using a torque wrench and flare wrench, tighten the upstream fitting first. For 3/16" brake line, torque to 11-13 ft-lbs; for 1/4" line, torque to 13-15 ft-lbs. Use a backup wrench on the component body to prevent twisting. Repeat for downstream fitting. Do not overtighten as this will damage the flare and cause leaks or fitting failure.
8. 8

   Inspect for interferences
   Manually cycle the suspension through its full travel range (push down and pull up on suspension components). Turn the steering wheel lock-to-lock if the line is near steering components. Verify the brake line does not contact or interfere with any moving parts, suspension travel, or steering operation. Reposition mounting clips if needed.
9. 9

   Bleed brake system at affected corner
   Fill the brake fluid reservoir with fresh DOT 4 brake fluid to the MAX line. Attach vacuum bleeder to the bleeder valve on the caliper or wheel cylinder served by the replaced line. Open the bleeder valve and draw fluid through until no air bubbles appear in the discharged fluid (typically 1-2 cups). Close bleeder valve and remove vacuum tool. If pedal bleeding, have assistant pump brake pedal 3 times and hold; open bleeder valve until fluid stops flowing, then close valve before pedal reaches floor. Repeat until no air bubbles appear.
10. 10

    Bleed remaining brake system
    Bleed the remaining three wheels in the sequence specified by Rivian (typically right rear, left rear, right front, left front for most vehicles). This ensures all air introduced during line replacement is purged from the entire system. Maintain brake fluid reservoir level above MIN throughout bleeding process. Top off reservoir to MAX line when complete.
11. 11

    Pressure test brake system
    With vehicle still raised on jack stands, have an assistant firmly press the brake pedal. Inspect all connections on the new brake line for signs of leakage. Check that the pedal feels firm and does not slowly sink to the floor. If pedal feels soft or spongy, additional bleeding is required. If any leaks are present, relieve pressure, check torque values and flare condition.

Reassembly

1. Reinstall wheel if removed and hand-tighten lug nuts
2. Lower vehicle from jack stands to ground
3. Torque wheel lug nuts to specification in star pattern
4. Dispose of old brake fluid according to local environmental regulations; never pour down drains
5. Clean any brake fluid spills from chassis and components immediately with water

Verification

• Verify brake fluid reservoir is at MAX level with DOT 4 brake fluid
• Start vehicle and verify no brake warning lights illuminate on dashboard
• With vehicle still in park, pump brake pedal firmly 10 times; pedal should feel firm and consistent with no sponginess
• Perform a low-speed brake test in a safe area: at 5-10 mph, apply brakes firmly to verify even stopping with no pulling to either side
• Perform a moderate-speed brake test at 20-25 mph in a safe area to confirm full braking performance
• Inspect under vehicle for any brake fluid leaks at the new line connections after test drive
• If any concerns exist with pedal feel, stopping performance, or fluid leaks, DO NOT DRIVE and have the system inspected by a professional immediately

More procedures for this vehicle