Brake Hose - Rear

This procedure replaces the rear brake hose on a 2024 Rivian EDV 500, requiring brake system depressurization, hose removal, installation of new hose, and complete brake system bleeding.

Warnings

Tools required

Parts

• Rear brake hose assembly × 1 — Use OEM Rivian specification
• Brake hose mounting bracket bolts (if corroded) × 2 — Use OEM specification
• Copper crush washers for banjo bolt (if applicable) × 2 — Use OEM specification
• Brake line clips (as needed) × 2 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level ground and place wheel chocks at front wheels
2. Put vehicle in Park and engage parking brake (will be released later)
3. Using Rivian diagnostic tool, place vehicle in Service Mode to disable high-voltage systems and deactivate regenerative braking
4. Verify Service Mode is active by checking dashboard indicators
5. Remove approximately half of the brake fluid from the master cylinder reservoir using a turkey baster or fluid extractor to prevent overflow during hose removal
6. Loosen rear wheel lug nuts while vehicle is on ground
7. Raise rear of vehicle using floor jack at designated rear lift point
8. Secure vehicle on jack stands rated for at least 7,000 lbs at proper lift points
9. Remove rear wheel on the side requiring brake hose replacement
10. Release parking brake
11. Identify the brake hose routing from chassis hard line to caliper, noting position of mounting brackets and clips
12. Clean brake hose connection areas with wire brush and penetrating lubricant if corrosion is present

Procedure

1. 1

   Disconnect brake hose from caliper
   Using a flare nut wrench, carefully loosen the banjo bolt (or threaded fitting, depending on configuration) connecting the brake hose to the rear caliper. Have a drain pan positioned below. If using banjo bolt configuration, note the position of copper crush washers on both sides of the fitting. Once loose, remove the bolt/fitting completely and immediately plug the caliper port with a plastic cap to prevent fluid loss and contamination. Note: some brake fluid will drain; this is normal.
2. 2

   Disconnect brake hose from chassis hard line
   Locate where the flexible brake hose connects to the rigid brake line at the chassis. This is typically a threaded flare fitting. Using a flare nut wrench on the brake hose fitting and a standard wrench on the chassis hard line nut (to prevent line twist), carefully loosen the connection. Work slowly to avoid rounding the fitting. Once loose, unthread completely. Immediately cap both the hard line and the brake hose end with plastic plugs to prevent fluid loss and air entry.
3. 3

   Remove brake hose mounting brackets
   The brake hose is secured to the chassis or suspension components by one or more mounting brackets or clips. Locate these brackets (typically one near the chassis hard line connection and possibly another mid-span). Remove the retaining bolts or clips securing the brake hose to these brackets. On Rivian vehicles, these may be 10mm or 12mm bolts. If clips are used, carefully pry them free without damaging surrounding components. Keep hardware for reinstallation or replacement.
4. 4

   Remove old brake hose
   With all connections and mounting points released, carefully remove the old brake hose from the vehicle. Inspect the hose for the failure mode (swelling, cracking, leaking, chafing) to ensure the replacement addresses the issue. Check that no additional damage exists to surrounding components. Dispose of old brake hose properly according to local regulations.
5. 5

   Inspect and prepare new brake hose
   Remove new brake hose from packaging and verify it matches the OEM configuration exactly, including length, fittings, and mounting bracket positions. Check that all fittings are clean and free of debris. If using banjo bolt configuration, ensure new copper crush washers are included (never reuse old washers). Verify the hose is not twisted or kinked. Pre-route the hose mentally to ensure proper installation path.
6. 6

   Install new brake hose to chassis mounting brackets
   Begin installation by routing the new brake hose along the proper path from chassis to caliper, ensuring it will not contact suspension components, steering linkage, or tire through full range of motion. Install the hose into chassis mounting brackets first, securing with retaining bolts or clips. Ensure the hose is positioned to allow for suspension travel without stretching or kinking. Do not fully tighten mounting bolts yet; leave slight movement for alignment.
7. 7

   Connect brake hose to chassis hard line
   Remove the plug from the chassis hard line. Remove the plug from the brake hose end. Thread the brake hose fitting onto the chassis hard line by hand, ensuring it threads smoothly without cross-threading. Once hand-tight, use a flare nut wrench on the hose fitting and back-up wrench on the hard line to tighten. Tighten to approximately 10-12 ft-lbs, then add approximately 1/6 turn (60 degrees). The fitting should feel snug but not over-torqued. Verify no cross-threading occurred.
8. 8

   Connect brake hose to caliper
   Remove the plug from the caliper port. For banjo bolt configuration: position new copper crush washers on both sides of the banjo fitting, align the banjo with the caliper port, and install the banjo bolt by hand. Tighten to approximately 18-22 ft-lbs. For threaded fitting: thread by hand first to ensure no cross-threading, then tighten to approximately 12-15 ft-lbs plus 1/6 turn. Ensure the brake hose is not twisted at either end.
9. 9

   Verify brake hose routing and clearances
   With both ends connected, verify the brake hose routing one final time. Turn the steering to full lock in both directions and compress/extend the suspension by pushing down on the vehicle to simulate travel. Ensure the brake hose has adequate clearance from all moving components, tire, and suspension parts with at least 0.5 inches clearance minimum. Adjust mounting bracket positions if needed, then tighten all mounting bracket bolts securely.
10. 10

    Bleed rear brake circuit
    Fill master cylinder reservoir to MAX line with fresh DOT 4 brake fluid. Starting with the wheel where the hose was replaced, attach brake bleeding kit to caliper bleeder screw. Open bleeder screw 1/2 turn and use either a pressure bleeder or manual bleeding method (assistant pumps brake pedal 3-4 times and holds, you open bleeder, close before pedal reaches floor, repeat). Continue until fluid runs clear with no air bubbles. Close bleeder screw. Check master cylinder level frequently and refill as needed. Never let it run dry.
11. 11

    Bleed remaining brake circuits
    Follow proper bleeding sequence for Rivian EDV 500 (typically: right rear, left rear, right front, left front, but verify with service documentation). Bleed each wheel using same procedure as previous step until all air is purged and firm pedal is achieved. This is critical for safety. Check all brake hose connections for leaks during bleeding process. Top off master cylinder to MAX line when complete.
12. 12

    Final inspection and leak check
    With assistant in driver seat, have them apply firm, steady pressure to brake pedal (approximately 50 lbs force) and hold for 30 seconds. Inspect all brake hose connections, banjo bolts, and fittings for any signs of leakage. Check that pedal remains firm and does not slowly sink. Wipe all connections dry and repeat inspection. If any leaks are detected, immediately address before proceeding. Check master cylinder fluid level and top off if needed.

Reassembly

1. Reinstall rear wheel and hand-tighten lug nuts in star pattern
2. Lower vehicle from jack stands using floor jack
3. Remove jack stands and lower vehicle completely to ground
4. Torque wheel lug nuts to manufacturer specification (typically 150 ft-lbs for Rivian EDV 500) in star pattern
5. Remove wheel chocks
6. Using Rivian diagnostic tool, exit Service Mode and restore vehicle to normal operation
7. Check master cylinder fluid level one final time and adjust to MAX line if needed
8. Ensure master cylinder reservoir cap is properly sealed

Verification

• With vehicle running (Ready mode), pump brake pedal several times - pedal should feel firm and consistent with normal operation
• Perform stationary brake pedal test: apply firm pressure and hold for 60 seconds - pedal should not sink or feel spongy
• Perform low-speed brake test in safe area: at 5-10 mph, apply brakes firmly - vehicle should stop straight without pulling, and pedal should feel normal
• Inspect all brake hose connections for any signs of fluid seepage or leaks
• Verify brake hose has proper clearance from all suspension and steering components through full range of motion
• Check that brake warning lights are not illuminated on dashboard
• Perform test drive at gradually increasing speeds up to 25 mph, testing brakes multiple times - braking should be smooth, straight, and responsive
• After test drive, re-inspect all connections for leaks while brakes are warm
• If any abnormalities are detected (soft pedal, pulling, noise, leaks), DO NOT drive vehicle - diagnose and repair immediately
• Schedule a follow-up inspection after 50-100 miles to verify all connections remain secure and leak-free

Related trouble codes on this vehicle

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