Brake Lines - Complete Set

Complete replacement of all brake lines on the 2024 Rivian EDV 500, including front-to-rear hard lines and flexible hoses at all four wheels.

Warnings

Tools required

Parts

• Complete brake line set (OEM or pre-bent aftermarket kit) × 1 — Use OEM specification for EDV 500
• Brake line retaining clips × 1 — Use OEM specification
• Brake line mounting grommets × 1 — Use OEM specification
• Flexible brake hose washers/seals (front) × 2 — Use OEM specification
• Flexible brake hose washers/seals (rear) × 2 — Use OEM specification
• Brake line unions/connectors (if splicing) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal to prevent electrical issues during service
3. Raise vehicle on lift or secure on jack stands at all four corners, ensuring stability
4. Remove all four wheels to access brake line connections at calipers
5. Place brake fluid catch containers under master cylinder and at expected drip points
6. Apply penetrating oil to all brake line fittings and allow 15-30 minutes to soak
7. Photograph or diagram existing brake line routing, clip positions, and connections for reference during installation
8. Verify replacement brake line kit is complete and matches vehicle specifications
9. Inspect high-voltage battery shield and underbody panels; remove panels that obstruct brake line access per Rivian service manual
10. Have Rivian diagnostic software ready to clear any brake system fault codes after service

Procedure

1. 1

   Drain brake fluid from master cylinder
   Using a turkey baster or fluid extraction pump, remove as much brake fluid as possible from the master cylinder reservoir to minimize spillage during line removal. Leave reservoir cap loose but in place to prevent vacuum formation. Dispose of old brake fluid properly according to local regulations.
2. 2

   Remove front flexible brake hoses
   Starting at the front wheels, use appropriate flare nut wrench to disconnect flexible brake hoses from hard lines at frame mounting points. Hold the hose end fitting stationary while loosening the hard line nut to prevent twisting. Cap open hard line ends immediately with plastic caps. Remove hose retaining clips and banjo bolts at calipers (if applicable), capturing crush washers. Cap caliper ports.
3. 3

   Remove rear flexible brake hoses
   Repeat process for rear brake hoses, disconnecting from hard lines at frame or axle mounting points. Use flare nut wrenches to prevent rounding fittings. Remove retaining clips and disconnect at calipers. Cap all open ports immediately to prevent contamination and fluid loss.
4. 4

   Disconnect brake lines at master cylinder and ABS modulator
   Carefully access the master cylinder and ABS modulator connections (typically in engine bay area). Use correct size flare nut wrench to loosen brake line nuts at master cylinder ports and ABS unit connections. Note which line connects to which port. Support lines during removal to prevent bending adjacent lines. Cap all open ports immediately.
5. 5

   Remove all line retaining clips and brackets
   Working from front to rear along frame rails and underbody, remove all brake line retaining clips, brackets, and grommets. Use photographs taken during preparation to ensure all attachment points are documented. Label or mark clips by location if they are not identical. Inspect clips for damage or corrosion; replace as needed.
6. 6

   Remove old hard brake lines
   Carefully extract old brake lines from vehicle, working section by section. Note exact routing path, especially where lines pass through frame holes, near suspension components, or around the battery pack. Verify lines do not contact high-voltage components or exhaust heat sources. Measure overall length of each section if fabricating custom lines.
7. 7

   Prepare and inspect new brake lines
   Lay out new brake line kit and verify all pieces are present and match old lines in length and end fittings. If using pre-bent kit, compare directly to old lines. If fabricating, cut nickel-copper or stainless steel brake line to measured lengths using tubing cutter (never hacksaw). Deburr cut ends thoroughly inside and out. Ensure all flare fittings are clean and undamaged.
8. 8

   Flare brake line ends (if fabricating)
   Using double flaring tool, create proper SAE double flares on all cut line ends. Ensure tubing is inserted to correct depth in flaring tool. First create initial cone, then form final double flare. Inspect each flare for cracks, splits, or improper formation. Reject and re-cut/re-flare any imperfect flares. This step is CRITICAL for safe operation.
9. 9

   Install main brake lines along frame rails
   Starting at master cylinder/ABS modulator end, route new hard lines along frame rails following exact path of original lines. Install lines through all frame holes and grommets. Ensure lines do not contact high-voltage battery enclosure, suspension arms, or steering components through full range of motion. Maintain minimum 1-inch clearance from heat sources and moving parts. Hand-thread fittings at master cylinder and ABS modulator but do not tighten yet.
10. 10

    Secure brake lines with retaining clips
    Install all brake line retaining clips, brackets, and grommets at original locations. Ensure lines are properly seated in clips without distortion or kinking. Lines should be secure but not under tension. Verify no contact with frame edges, battery components, or suspension through full suspension travel and steering range. Replace any damaged clips or grommets with new parts.
11. 11

    Install new flexible brake hoses
    Install new flexible brake hoses at all four wheels using new crush washers or seals. Connect to hard lines at frame mounting points, ensuring hoses are not twisted. Flexible hoses should have slight slack and not contact suspension components through full range of travel. Install retaining clips at frame mounts. Connect to calipers with new sealing washers on banjo bolts. Hand-tighten all connections initially.
12. 12

    Tighten all brake line connections
    Working systematically from master cylinder to wheels, tighten all brake line fittings. Use flare nut wrenches to prevent rounding. Tighten flare fittings snugly (typically 10-12 ft-lbs for 3/16" lines, but do not exceed manufacturer specifications). Do not overtighten, as this can distort flares and cause leaks. Tighten banjo bolts at calipers to specification (typically 18-22 ft-lbs for Rivian, but verify). Since no torque specifications are provided in database, tighten to industry-standard values: flare nuts snug plus 1/6 turn, banjo bolts 20 ft-lbs unless otherwise marked.
13. 13

    Fill brake system and perform initial bleeding
    Fill master cylinder reservoir with fresh DOT 4 brake fluid to MAX line. Using vacuum bleeder or pressure bleeder, begin bleeding brake system starting at wheel furthest from master cylinder (typically right rear, then left rear, right front, left front). Open bleeder valve at each caliper and allow fluid to flow until clear, bubble-free fluid emerges. Maintain reservoir level throughout bleeding process. If vehicle has electronic brake assist, cycling ignition or using diagnostic software may be required for complete bleed.
14. 14

    Perform comprehensive leak inspection
    With system bled and reservoir full, have assistant apply firm, steady brake pedal pressure (approximately 50 lbs force) and hold for 2 minutes. Inspect every connection, fitting, flare, and hose junction for signs of fluid seepage or dripping. Check master cylinder, ABS modulator, all hard line unions, flexible hose connections, and caliper banjo fittings. Any leak requires immediate correction—drain section, repair or replace affected component, and re-bleed. Repeat pedal pressure test after any repairs.
15. 15

    Final system bleed and pedal verification
    Perform final complete brake system bleed cycle at all four wheels. Pump brake pedal 20-30 times, then hold firm pressure. Pedal should feel firm and high with minimal travel. If pedal is soft or sinks, continue bleeding or check for leaks. Top off master cylinder reservoir to MAX line. Install reservoir cap. Use diagnostic software to clear any brake system fault codes. Verify no warning lights remain on instrument cluster.

Reassembly

1. Reinstall any underbody panels or battery shields removed for access, ensuring no contact with brake lines
2. Install all four wheels and torque lug nuts to Rivian specification (typically 150 ft-lbs for EDV 500, verify in owner's manual)
3. Reconnect 12V battery negative terminal
4. Lower vehicle to ground and remove jack stands or lift
5. Check brake fluid level one final time and top off if needed
6. Start vehicle and verify brake warning lights extinguish after initial system check

Verification

• With vehicle running, pump brake pedal several times and verify firm, high pedal with no sponginess or excessive travel
• Perform stationary brake test: with vehicle in Park/Drive and parking brake released, verify service brake holds vehicle stationary with moderate pedal pressure
• Check master cylinder reservoir level and verify no leaks at reservoir or connections after pedal application
• Perform low-speed rolling brake test in safe area: at 5-10 mph, apply brakes gently and verify straight, smooth stopping with no pulling or noise
• Increase speed to 15-20 mph and perform moderate brake application, verifying firm pedal and straight stopping
• Inspect all brake line connections, fittings, and flexible hoses one final time for any signs of leakage or seepage
• Verify no brake warning lights on instrument cluster and no fault codes stored using diagnostic software if available
• Test ABS function (if safe to do so) by performing hard braking on low-traction surface, verifying pedal pulsation and system engagement
• Before returning vehicle to service, perform final check of brake pedal feel and response—pedal MUST be firm and high
• Document brake line replacement in vehicle service records with date and mileage

More procedures for this vehicle