Brake Line - Single

Replace a single damaged or corroded brake line on the 2025 Rivian EDV 500, including bleeding the brake system and verifying proper operation.

Warnings

Tools required

Parts

• OEM brake line assembly or pre-bent replacement × 1 — Use OEM specification for specific line location
• Brake line fittings (if fabricating custom line) × 2 — Match thread pitch and size to original
• Brake line mounting clips × 2 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level ground and place wheel chocks behind wheels that will remain on the ground
2. Put vehicle in Park and ensure high-voltage system is shut down (consult owner's manual for proper shutdown procedure)
3. Identify which brake line needs replacement by inspecting for damage, corrosion, or leaks
4. Take detailed photos of the line routing, mounting clip locations, and fitting positions before removal
5. If replacing a pre-bent OEM line, verify you have the correct replacement part for the specific line location (front-to-rear, left-to-right, etc.)
6. If fabricating a custom line, measure the damaged line or create a template with wire before removal
7. Raise and support vehicle on jack stands at appropriate lift points specified in owner's manual
8. Remove wheel(s) if necessary to access the damaged brake line
9. Have a drain pan ready to catch brake fluid during line removal

Procedure

1. 1

   Relieve brake system pressure
   With the vehicle powered off, pump the brake pedal 15-20 times until it feels firm and resistant. This depletes any residual hydraulic pressure and vacuum assist in the system.
2. 2

   Remove damaged brake line from fittings
   Using the appropriate size flare nut wrench, carefully loosen the brake line fittings at both ends. If fittings are corroded, apply penetrating oil and wait 10-15 minutes. Turn fittings counterclockwise slowly to avoid rounding off. Allow brake fluid to drain into the pan. Cap or plug open ports immediately with clean rubber caps or plastic plugs to prevent contamination.
3. 3

   Remove mounting clips
   Locate all mounting clips securing the brake line to the chassis, suspension components, or body. Remove clips by pressing release tabs, prying carefully, or removing retaining hardware. Note the exact position and orientation of each clip for reinstallation. Keep clips if reusable.
4. 4

   Remove damaged brake line
   Carefully extract the brake line from its routing path, noting any grommets, protective sleeves, or points where the line passes through chassis members. Inspect the routing path for sharp edges or debris that may have caused the original failure.
5. 5

   Prepare replacement brake line
   If using a pre-bent OEM line, verify it matches the original routing and fitting positions. If fabricating a custom line, cut brake line tubing to length using a tubing cutter (not a hacksaw) to ensure a clean, square cut. Deburr the cut ends thoroughly. Create double flares at both ends using a flaring tool according to the tool manufacturer's instructions. Verify flares are symmetrical and free of cracks.
6. 6

   Bend and route new brake line
   If fabricating, carefully bend the new line to match the original routing using a brake line bending tool or by hand, avoiding kinks or sharp bends that could restrict flow. Minimum bend radius should be at least 3 times the line diameter. Route the new line through all mounting points, grommets, and chassis passages following the original path exactly.
7. 7

   Install mounting clips
   Install mounting clips at all original locations before tightening fittings. Ensure clips secure the line firmly without crushing it. The line should not vibrate or rub against any components. Maintain proper clearance from suspension, steering, exhaust, and high-voltage components.
8. 8

   Connect brake line fittings
   Thread brake line fittings by hand into both ports (master cylinder, junction block, caliper, or wheel cylinder as applicable) to ensure proper engagement. Once hand-tight, use a flare nut wrench to tighten to manufacturer specification (typically 11-13 ft-lbs for metric brake lines). Do not over-tighten. Support the component body with a backup wrench to prevent twisting.
9. 9

   Inspect installation
   Verify the new brake line is properly routed with adequate clearance, all mounting clips are secure, fittings are tight, and there are no kinks or damage. Check that the line does not interfere with steering, suspension travel, or wheel rotation through full range of motion.
10. 10

    Fill brake fluid reservoir
    Open the brake fluid reservoir and fill to the MAX line with fresh DOT 4 brake fluid from a sealed container. Keep the reservoir at least half-full throughout the bleeding process.
11. 11

    Bleed brake system
    Bleed the brake system starting with the wheel furthest from the master cylinder (typically right rear), then left rear, right front, and left front. For each wheel: attach clear tubing to the bleeder screw with the other end submerged in clean brake fluid in a container. Have an assistant pump the brake pedal 3-5 times and hold down. Open the bleeder screw 1/2 turn until fluid flows, then close before pedal reaches the floor. Repeat until fluid flows clear without air bubbles. Check reservoir level frequently and refill as needed. For vehicles with ABS, a scan tool may be required to activate the ABS pump and cycle valves for complete bleeding.
12. 12

    Check for leaks
    With the system bled and reservoir filled to MAX, have an assistant apply firm, steady pressure to the brake pedal (approximately 50 lbs force) and hold for 30 seconds. Inspect all fittings and connections along the new brake line for any signs of fluid seepage. Wipe fittings dry with a clean cloth, then reapply pressure and check again.
13. 13

    Test brake pedal feel
    With the vehicle still on jack stands and powered off, pump the brake pedal several times. It should feel firm and consistent. A spongy pedal indicates air in the system requiring additional bleeding. The pedal should not sink slowly to the floor when held under pressure.

Reassembly

1. Reinstall wheels if removed and torque lug nuts to specification
2. Lower vehicle from jack stands
3. Top off brake fluid reservoir to MAX line with fresh DOT 4 brake fluid
4. Clean any brake fluid spills from painted surfaces immediately with water
5. Dispose of used brake fluid properly at a recycling center

Verification

• Start the vehicle and verify the brake warning light is not illuminated on the dashboard
• With the vehicle stationary, apply the brakes firmly and verify solid pedal feel with no sponginess or unusual travel
• Perform a low-speed brake test in a safe area to verify proper braking function. The vehicle should stop straight without pulling to one side
• Perform a test drive at various speeds, testing both light and firm brake applications. Verify the regenerative braking system functions normally
• After the first test drive, immediately recheck all fittings for leaks while the system is warm and at full pressure
• Check brake fluid level after test drive and top off if necessary
• Recheck all fittings and line routing after 50-100 miles of driving to ensure no leaks have developed
• If brake pedal feel is abnormal, ABS light is illuminated, or any leaks are detected, DO NOT DRIVE and have the vehicle towed to a professional for diagnosis

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