Brake Hose - Rear

Replace the rear brake hose on a 2025 Rivian EDV 500, including bleeding the brake system to restore proper braking function.

Warnings

Tools required

Parts

• Rear brake hose × 1 — Use OEM Rivian specification
• Brake hose mounting clips or retainers × 1 — Use OEM specification if damaged
• Copper crush washers for banjo bolt × 4 — Use OEM specification - typically 2 per connection

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on a level, solid surface and apply parking brake firmly
2. Place wheel chocks in front of the front wheels
3. Open the hood and locate the brake fluid reservoir - check fluid level and condition
4. DO NOT disconnect the 12V battery as this may affect brake system electronics and bleeding procedures
5. Loosen the rear wheel lug nuts 1/4 turn while vehicle is on the ground
6. Lift the rear of the vehicle using a floor jack at the designated rear lift point
7. Install jack stands rated for at least 10,000 lbs under proper support points
8. Lower vehicle onto jack stands and verify stability before proceeding
9. Remove the rear wheel completely on the side requiring hose replacement
10. Put on safety glasses and nitrile gloves - have brake cleaner and shop towels ready
11. Place a catch pan under the work area to collect brake fluid
12. If available, activate brake service mode through the vehicle's touchscreen interface to prevent automatic brake system functions

Procedure

1. 1

   Locate and inspect the rear brake hose
   Identify the rear brake hose running from the chassis hard line to the brake caliper or wheel cylinder. The hose is typically mounted with a bracket or clip at the chassis. Inspect the connection points at both ends - note whether it uses banjo bolts or threaded fittings. Clean the area around both connections with brake cleaner to remove dirt and corrosion.
2. 2

   Prepare the upper connection at chassis hard line
   Apply penetrating oil to the connection between the brake hose and the chassis hard line if there is visible corrosion. Wait 5-10 minutes for penetration. This connection is typically a threaded fitting or banjo bolt. Position your catch pan directly below this connection point as fluid will drain when opened.
3. 3

   Disconnect the brake hose from chassis hard line
   Using the appropriate flare nut wrench (typically 10mm or 12mm), carefully loosen the fitting at the chassis end of the brake hose. If it's a banjo bolt, hold the hose body with an open-end wrench while loosening the banjo bolt. Work slowly to avoid stripping the soft brass fittings. Once loose, allow brake fluid to drain into the catch pan. Remove the old copper crush washers if present and discard them - never reuse these washers.
   ⚠Use only a flare nut wrench on brake line fittings. Standard wrenches can round off the soft brass fittings, making removal extremely difficult.
4. 4

   Remove chassis mounting bracket or clip
   Locate the bracket or clip that secures the brake hose to the chassis or suspension component. This may be a metal clip, rubber grommet, or bracket with a bolt. Remove the retaining hardware and note its orientation for reinstallation. The hose should now be free at the upper end.
5. 5

   Disconnect the brake hose from caliper
   At the caliper end, the brake hose is typically connected with a banjo bolt. Hold the hose fitting with an open-end wrench to prevent it from twisting, then use another wrench to loosen the banjo bolt. Once loose, remove the bolt completely and separate the hose from the caliper. Remove and discard both copper crush washers from the banjo fitting. Keep the banjo bolt - it will be reused with new crush washers.
   ⚠Do not allow the brake caliper to hang by the flexible hose or twist during removal. Support the caliper with wire if necessary.
6. 6

   Remove the old brake hose completely
   With both ends disconnected and the mounting bracket removed, carefully extract the old brake hose from the vehicle. Immediately plug the open hard line at the chassis using a clean rubber cap or plug to minimize fluid loss and prevent contamination. Inspect the old hose for damage, cracking, swelling, or fluid leakage to confirm replacement was necessary.
7. 7

   Prepare and install the new brake hose upper connection
   Unpack the new brake hose and verify it matches the old hose in length, fitting types, and routing path. Install the new hose into the chassis mounting bracket or clip first to establish proper routing. If using a banjo connection at the chassis, place a NEW copper crush washer on each side of the banjo fitting. Thread the fitting or banjo bolt into the chassis hard line by hand, ensuring it threads smoothly without cross-threading. Hand-tighten only at this stage.
8. 8

   Route and secure the new brake hose
   Route the new brake hose along the same path as the original, ensuring it does not contact any sharp edges, moving suspension components, or the tire at full lock and full suspension travel. Secure the hose in the chassis mounting bracket or clip, ensuring the clip is fully seated. The hose should have slight slack to allow for suspension movement but not be loose enough to chafe or kink.
9. 9

   Connect the new brake hose to the caliper
   At the caliper connection, install a NEW copper crush washer on the banjo bolt, insert the bolt through the brake hose banjo fitting, add another NEW copper crush washer on the other side, then thread the bolt into the caliper. Hand-tighten the banjo bolt initially. Ensure the hose is not twisted - the hose routing should be natural without any spiral or kinks.
   ⚠️Always use NEW copper crush washers on banjo bolt connections. Reusing old washers will result in brake fluid leaks and potential brake failure.
10. 10

    Torque all brake hose connections
    Since specific torque values are not provided in the database, consult the Rivian service manual for exact specifications. Typical brake hose banjo bolts require 18-22 ft-lbs, and threaded fittings require 10-14 ft-lbs, but these are general ranges only. Use a calibrated torque wrench and tighten the chassis connection first, then the caliper connection. Do not over-tighten as this can damage fittings or strip threads.
    ⚠️CRITICAL: Obtain the correct torque specifications from the Rivian service manual before tightening. Incorrect torque can cause brake fluid leaks or fitting failure.
11. 11

    Refill the brake fluid reservoir
    Open the brake fluid reservoir cap under the hood. Using a clean funnel, fill the reservoir to the MAX line with fresh DOT 4 brake fluid from a sealed container. Do not use fluid from a previously opened container as it may have absorbed moisture. Keep the reservoir filled throughout the bleeding process to prevent introducing more air into the system.
12. 12

    Bleed the rear brake circuit
    Attach a clear plastic hose to the bleeder valve on the rear caliper and place the other end in a container partially filled with fresh brake fluid. Have an assistant pump the brake pedal 3-5 times and hold pressure on the pedal. Open the bleeder valve approximately 1/4 turn while pedal is held down - fluid and air bubbles will flow out. Close the bleeder valve before the pedal reaches the floor. Repeat this process until no air bubbles are visible in the fluid stream and only clear fluid emerges. Check and refill the reservoir frequently during bleeding.
    ⚠️Never allow the brake fluid reservoir to run empty during bleeding. This will introduce air into the entire brake system requiring complete system bleeding.
13. 13

    Bleed remaining brake circuits if necessary
    For the Rivian EDV 500 with advanced braking systems, you may need to bleed other circuits or use a scan tool to activate the ABS pump. Follow the bleeding sequence: right rear, left rear, right front, left front. If the pedal remains soft after bleeding all corners, a pressure bleeder or scan tool with brake bleeding function may be required to purge air from the ABS modulator.
    ℹ️Electric vehicles with regenerative braking may require special bleeding procedures. Consult Rivian service information if standard bleeding does not restore firm pedal feel.
14. 14

    Inspect all connections for leaks
    With the brake system bled, have your assistant apply firm pressure to the brake pedal and hold for 30 seconds. While pedal pressure is maintained, carefully inspect both ends of the new brake hose for any signs of fluid seepage or dripping. Check the banjo bolt connections and threaded fittings. Wipe all connections dry with a clean shop towel and repeat the pressure test. Any fluid seepage indicates a leak that must be corrected before driving.
15. 15

    Reinstall the wheel and lower the vehicle
    Clean the wheel hub face and wheel mounting surface of any dirt or rust. Install the wheel and hand-tighten all lug nuts in a star pattern. Lower the vehicle from the jack stands using the floor jack until the tire just touches the ground. Remove the jack stands and lower the vehicle completely. Torque the wheel lug nuts to specification (typically 140-150 ft-lbs for this vehicle) in a star pattern using a calibrated torque wrench.

Reassembly

1. Double-check that all brake line connections are properly torqued and show no signs of leakage
2. Verify the brake hose is properly secured in its mounting bracket and does not contact any moving parts
3. Ensure the brake fluid reservoir is filled to the MAX line with fresh DOT 4 fluid
4. Confirm all wheels are properly torqued and secure
5. Remove all tools, equipment, and drain pans from under and around the vehicle

Verification

• Before moving the vehicle, pump the brake pedal several times - it should feel firm with normal resistance. A soft or spongy pedal indicates air remains in the system and further bleeding is required
• Start the vehicle and verify no brake warning lights are illuminated on the dashboard
• With the vehicle still stationary, apply firm brake pedal pressure and hold for 60 seconds - the pedal should not slowly sink toward the floor. Any sinking indicates a leak or air in the system
• Perform a careful low-speed test drive in a safe area, testing the brakes at 5-10 mph to verify proper braking function before normal driving
• After the test drive, re-inspect all brake hose connections for any signs of fluid leakage
• Check brake pedal feel during the test drive - it should be firm and provide consistent braking force without pulsation or unusual noises
• If any abnormalities are detected (soft pedal, leaks, warning lights, unusual noises), DO NOT DRIVE the vehicle. Have it towed to a qualified technician for diagnosis
• Re-check the brake fluid level after test drive and top off if needed - some additional fluid may be displaced during initial brake applications
• Schedule a follow-up inspection after 50-100 miles to re-check all connections for leaks and verify continued proper brake operation

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