Brake Lines - Complete Set

Complete replacement of all brake lines on the 2025 Rivian EDV 500, including front, rear, and intermediate hard lines and flexible hoses. This is a safety-critical procedure requiring complete brake system evacuation, line replacement, and thorough bleeding.

Warnings

Tools required

Parts

• Complete brake line kit for EDV 500 × 1 — Use OEM Rivian specification
• Brake line mounting clips × 10 — OEM or equivalent
• Banjo bolt sealing washers × 8 — OEM copper washers
• Brake line fittings (if fabricating lines) × 1 — M10x1.0 and M12x1.0

Fluids

• DOT 4 Brake Fluid — 2 qt

Preparation

1. Review Rivian service manual for brake system layout specific to EDV 500 configuration
2. Ensure scan tool is charged and updated with latest Rivian software for brake system bleeding and recalibration procedures
3. Park vehicle on level surface and chock rear wheels securely
4. Place vehicle in Park mode and engage parking brake initially (will be released later)
5. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes for system capacitors to discharge
6. Lift vehicle using approved lift points per Rivian service manual and support on jack stands at all four corners
7. Remove all four wheels and set aside
8. Place large catch pans under vehicle to collect brake fluid
9. Photograph brake line routing from multiple angles for reference during installation
10. Apply penetrating oil to all brake line fittings and allow to soak for 15-30 minutes

Procedure

1. 1

   Evacuate brake fluid from reservoir
   Using a fluid evacuator or turkey baster, remove as much brake fluid as possible from the master cylinder reservoir. This minimizes spillage during line removal. Dispose of old brake fluid according to local hazardous waste regulations. Do not reuse old brake fluid.
2. 2

   Remove rear brake flexible hoses
   Starting at the rear, locate flexible brake hoses connecting hard lines to rear calipers. Using flare nut wrenches, carefully loosen and remove banjo bolts at caliper ends first, allowing fluid to drain into catch pan. Cap or plug caliper ports immediately. Then disconnect hard line fittings at the chassis mounting points. Remove hose brackets from suspension components. Label lines 'LR' and 'RR' if not using complete kit.
3. 3

   Remove rear hard brake lines
   Trace rear brake lines from ABS module area to rear suspension mounting points. Using line wrenches, disconnect fittings at ABS module, intermediate junctions, and rear axle area. Remove all mounting clips securing lines to frame and underbody. Carefully extract lines, noting routing around suspension components, exhaust shields, and high-voltage battery pack. These lines run along frame rails and may be secured with multiple clips.
4. 4

   Remove front brake flexible hoses
   At front suspension, locate flexible hoses connecting hard lines to front calipers. Remove banjo bolts at calipers using flare nut wrench, cap caliper ports immediately. Disconnect hard line fittings at chassis junction points on both sides. Remove hose brackets from strut assemblies or control arms. Be careful not to damage ABS wheel speed sensor wiring routed nearby.
5. 5

   Remove front hard brake lines and master cylinder connections
   Disconnect brake lines at master cylinder or brake booster assembly under hood. You may need to remove plastic covers or access panels. Using line wrenches, carefully disconnect fittings at master cylinder ports. Trace front brake lines along frame rails to front suspension junction points. Remove all mounting clips and carefully extract lines. Note routing around steering components, front drive unit, and cooling system lines.
6. 6

   Inspect mounting points and clean connection areas
   With all old lines removed, inspect all mounting clips, brackets, and connection points for corrosion or damage. Clean all fitting threads at master cylinder, ABS module, and caliper ports using wire brush. Check that all threaded ports are undamaged. Replace any damaged mounting clips or brackets. Verify clearances for new line routing, especially near suspension travel limits and steering components.
7. 7

   Install front hard brake lines
   Beginning with front lines from master cylinder to front suspension junctions, route new brake lines following original path photographed during disassembly. Start threads by hand at master cylinder and ABS module connections to avoid cross-threading. Install mounting clips loosely to allow positioning adjustment. Ensure adequate clearance from suspension components, steering linkage, drive shafts, and heat sources. Lines must not contact sharp edges or moving parts throughout suspension travel range.
8. 8

   Install front flexible brake hoses
   Install new flexible hoses at front calipers using new copper sealing washers on banjo bolts. Hand-start threads at both caliper and hard line junction points. Ensure hoses have adequate slack and will not be stretched during full suspension compression or steering lock. Hoses must not twist or contact any components throughout full range of motion. Verify routing allows for full steering articulation.
9. 9

   Install rear hard brake lines
   Route rear brake lines from ABS module area to rear suspension junction points following original routing. Hand-start all fittings at ABS module and intermediate junctions. Install mounting clips along frame rails, ensuring lines are secure but not kinked. Maintain proper clearance from high-voltage battery pack components (minimum 25mm clearance from orange HV cables), rear drive unit, and suspension travel paths. Lines must be protected from road debris.
10. 10

    Install rear flexible brake hoses
    Install new flexible hoses at rear calipers with new copper sealing washers on banjo bolts. Hand-start threads at calipers and hard line junctions. Verify adequate slack for full suspension droop and compression. Secure hoses to suspension brackets ensuring no contact with CV shafts, control arms, or springs throughout full suspension travel. Check that hoses will not be damaged during maximum articulation.
11. 11

    Torque all brake line fittings
    Systematically torque all brake line connections starting from master cylinder and working toward calipers. Since no specific torque values are provided in database, use standard brake line torque specifications: M10x1.0 fittings to 11-13 ft-lbs, M12x1.0 fittings to 13-15 ft-lbs, and banjo bolts to 18-22 ft-lbs. Use flare nut wrenches to avoid rounding fittings. Double-check all connections are properly seated and torqued. Verify all mounting clips are secured.
12. 12

    Fill brake fluid reservoir and prepare for bleeding
    Fill master cylinder reservoir to MAX line with fresh DOT 4 brake fluid from sealed container. Connect pressure bleeder system to reservoir per manufacturer instructions, typically 15-20 PSI for bleeding. Alternatively, prepare for manual bleeding with assistant. Reconnect 12V auxiliary battery. Connect Rivian-compatible scan tool and power on vehicle to accessory mode (do not enable drive mode yet).
13. 13

    Bleed brake system using scan tool
    Using scan tool, access brake system bleeding function. Follow scan tool prompts to activate ABS pump and cycle valves during bleeding process. Bleed in sequence: RR, LR, RF, LF (or as directed by scan tool). At each wheel, attach clear hose to bleeder valve into catch bottle. Open bleeder valve 1/2 to 3/4 turn. Monitor fluid flow until clear, bubble-free fluid emerges. Close bleeder before pressure drops. Maintain reservoir level above MIN at all times. Repeat sequence 2-3 times until all wheels show clear fluid with no air bubbles.
14. 14

    Perform final system checks and recalibration
    Using scan tool, run brake system diagnostic checks to verify proper ABS module communication and sensor readings. Perform brake pedal calibration procedure as directed by scan tool. Check for any fault codes. Verify brake pedal feels firm with no sponginess after three pumps. Check all fittings and connections for leaks while assistant applies firm brake pedal pressure (do not start vehicle yet). Top off reservoir to MAX line with DOT 4 fluid.
15. 15

    Install wheels and perform operational test
    Reinstall all four wheels, torquing lug nuts to specification (typically 140-150 ft-lbs for EDV 500, verify in service manual). Lower vehicle from jack stands carefully. With vehicle still on lift or in safe area, enable drive mode and verify brake warning lights extinguish. Test brake pedal operation at idle - should be firm and hold steady pressure. Check all line routing one final time with vehicle at normal ride height.

Reassembly

1. Verify all brake line mounting clips are secured and lines have proper clearance from all moving components
2. Ensure no brake lines contact high-voltage orange cables or battery pack components
3. Confirm brake fluid reservoir is filled to MAX line with fresh DOT 4 fluid
4. Verify brake pedal has firm feel with no excessive travel or sponginess
5. Check that all tools and materials are removed from under vehicle
6. Ensure 12V auxiliary battery is properly reconnected with clean, tight connections

Verification

• Perform static brake pedal test: With vehicle in Park, pump brake pedal three times and hold firm pressure for 30 seconds. Pedal should remain firm with no sinking or sponginess
• Inspect all brake line fittings, connections, and junctions for any signs of fluid seepage or leaks while brake pedal is held under pressure
• Conduct low-speed brake test in safe area: Drive at 5-10 mph and apply brakes gently. Braking should be smooth and even with no pulling to either side
• Perform moderate brake test: At 20-25 mph in safe area, apply firm brakes. Vehicle should stop straight and true with no ABS fault lights or unusual pedal feel
• Verify regenerative braking coordination: Accelerate moderately and release accelerator. Regen braking should engage smoothly without friction brake involvement at normal levels
• Monitor brake warning lights on instrument cluster - all should remain off during normal operation
• Re-check brake fluid level after test drive - should remain between MIN and MAX marks
• Perform final inspection of all brake line routing with vehicle at operating temperature, checking for any contact points or heat damage
• Schedule follow-up inspection after 50-100 miles to re-check all fittings for leaks and verify proper brake operation
• CRITICAL: Before returning vehicle to normal service, perform emergency stop test in controlled environment to verify full braking capability at higher speeds

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