This procedure covers the removal and replacement of the ABS pump assembly on a 2025 Rivian EDV 500 electric delivery van, including brake fluid evacuation and system bleeding.

Warnings

Tools required

Parts

• ABS pump assembly × 1 — Use OEM Rivian specification
• ABS pump mounting gasket or seal × 1 — Use OEM Rivian specification
• Brake line copper washers (if applicable) × 4 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Open front hood and locate 12V battery in left front compartment
4. Disconnect 12V battery negative terminal and wait minimum 5 minutes for system capacitor discharge
5. Raise vehicle on lift or support securely on jack stands at manufacturer-specified lift points
6. Remove front driver-side wheel to improve access to ABS pump compartment
7. Locate ABS pump assembly in front driver-side wheel well area, mounted to frame rail
8. Place absorbent pads or drain pan beneath ABS pump assembly

Procedure

1. 1

   Evacuate brake fluid reservoir
   Using brake fluid evacuation tool or turkey baster, remove as much brake fluid as possible from the brake fluid reservoir to minimize spillage during line disconnection. Properly dispose of old brake fluid according to local regulations.
2. 2

   Remove underbody shield
   Remove the front underbody shield panels that restrict access to the ABS pump. Remove Torx fasteners (typically T25 or T30) securing the driver-side underbody panel and carefully lower the panel. Set aside fasteners in organized manner.
3. 3

   Disconnect ABS pump electrical connector
   Locate the main electrical connector on the ABS pump assembly. Press the locking tab and carefully disconnect the connector. If equipped with secondary connectors for wheel speed sensors routed through pump bracket, disconnect those as well. Move wiring harness clear of work area.
4. 4

   Label and disconnect brake lines
   Identify and label all brake lines connected to the ABS pump (typically 4-6 lines). Using appropriate flare nut wrenches (10mm or 11mm), carefully loosen each brake line fitting. Work slowly to avoid rounding fittings. Once loose, unthread by hand and immediately cap or plug open lines to prevent fluid loss and contamination. Position drain pan to catch residual fluid.
5. 5

   Remove ABS pump mounting fasteners
   Locate the mounting bolts securing the ABS pump assembly to the frame bracket (typically 3-4 bolts, 10mm or 13mm heads). Support the pump assembly weight with one hand while removing the final fastener. Remove all mounting hardware and set aside.
6. 6

   Remove ABS pump assembly
   Carefully maneuver the ABS pump assembly out of its mounting location, taking care not to damage surrounding components or high-voltage cables. The pump is heavy (approximately 10-15 lbs) and may have residual brake fluid. Keep oriented upright and place on clean workspace.
7. 7

   Prepare new ABS pump
   Remove new ABS pump from packaging and inspect for shipping damage. Transfer any brackets or hardware from old pump if not included with replacement. Install new mounting gasket or seal if applicable. Verify all protective caps are removed from brake line ports before installation.
8. 8

   Install new ABS pump
   Position new ABS pump assembly into mounting location, aligning with frame bracket holes. Start all mounting bolts by hand to ensure proper thread engagement. Torque mounting bolts in star pattern to manufacturer specification (if available, typically 15-20 ft-lbs for this application).
9. 9

   Reconnect brake lines
   Connect each brake line to its corresponding port on the new ABS pump according to labels created during removal. Install new copper crush washers if applicable. Hand-thread each fitting until snug, then tighten with flare nut wrench. Typical torque is 10-12 ft-lbs for brake line fittings. Do not overtighten as this can damage flare seats.
10. 10

    Reconnect electrical connector
    Reconnect the main electrical connector to the ABS pump, ensuring the locking tab fully engages with an audible click. Reconnect any secondary connectors. Verify all connections are secure and wiring is properly routed away from moving components and heat sources.
11. 11

    Refill brake fluid reservoir
    Fill the brake fluid reservoir to the MAX line with fresh DOT 4 brake fluid. Do not reuse old brake fluid. Keep reservoir topped off throughout the bleeding process.
12. 12

    Bleed brake system
    Using a Rivian-compatible scan tool, initiate the ABS pump bleeding procedure to cycle the internal valves. Follow the tool's prompts to bleed each wheel in the specified sequence (typically RR, LR, RF, LF). At each wheel, open bleeder valve and allow fluid to flow until free of air bubbles. Close bleeder before releasing brake pedal. Repeat until all air is purged. Continuously monitor and refill brake fluid reservoir to prevent introducing more air.
13. 13

    Reinstall underbody shield and wheel
    Reinstall the front underbody shield panel using all original fasteners. Torque Torx fasteners to manufacturer specification. Reinstall front driver-side wheel and torque lug nuts to specification (typically 140-150 ft-lbs for EDV 500).

Reassembly

1. Ensure all brake line connections are tight and free of leaks
2. Verify ABS pump electrical connector is fully seated and locked
3. Confirm brake fluid reservoir is filled to proper level with DOT 4 fluid
4. Double-check that all underbody shields and panels are properly secured
5. Reconnect 12V battery negative terminal

Verification

• With vehicle still raised, start engine and verify no brake fluid leaks at ABS pump connections
• Press brake pedal firmly and verify it feels solid with no excessive travel or sponginess
• Using scan tool, clear any ABS fault codes and verify ABS system shows no active faults
• Perform functional test: with vehicle on lift, verify each wheel can be locked and released independently when activating ABS through scan tool
• Lower vehicle and perform low-speed test drive in safe area, verifying normal brake operation
• Perform multiple hard stops from 25-30 mph to verify ABS engages properly (pulsing pedal)
• Recheck brake fluid level after test drive and top off if necessary
• Verify no warning lights remain illuminated on instrument cluster

More procedures for this vehicle