This procedure covers the removal and replacement of the third brake light (center high-mounted stop lamp) on the 2025 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Third brake light assembly × 1 — Use OEM specification
• Weatherstrip seal (if damaged) × 1 — Use OEM specification
• Mounting clips (if broken) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle and remove key fob from interior
3. Open rear cargo doors and secure in open position
4. Allow vehicle electrical systems to enter sleep mode (wait 10 minutes after vehicle shutdown)
5. Disconnect 12V auxiliary battery negative terminal located in front passenger compartment
6. Wait 5 minutes for capacitor discharge in lighting control modules
7. Protect cargo area floor with drop cloth or cardboard
8. Use masking tape to mark panel alignment and clip locations for reassembly reference

Procedure

1. 1

   Access cargo area headliner
   From inside the cargo area, identify the headliner panel directly below the third brake light position (center of roof at rear). Remove the rear cargo area LED light assemblies on each side by gently prying with plastic trim tool to release spring clips. Disconnect electrical connectors by pressing release tabs.
2. 2

   Remove headliner trim fasteners
   Locate and remove all T20 Torx screws securing the rear section of cargo area headliner. On EDV 500, there are typically 6-8 screws along the rear edge and sides. Remove plastic push-pin fasteners using panel tool by pressing center pin, then extracting entire fastener.
3. 3

   Lower headliner panel
   Carefully lower the rear section of headliner panel approximately 6-8 inches. Support the panel to prevent stress on remaining attachment points. You should now have access to the back side of the third brake light mounting area. Use work light to illuminate the workspace.
4. 4

   Disconnect third brake light electrical connector
   Locate the electrical connector attached to the back of the third brake light assembly. Press the connector release tab and pull straight back to disconnect. If equipped with a secondary locking tab (red or gray), slide it to the unlock position first. Note connector orientation for reinstallation.
5. 5

   Remove third brake light mounting fasteners
   Remove the mounting fasteners securing the third brake light assembly to the roof structure. On EDV 500, this typically consists of four 10mm nuts or T25 Torx screws accessed from inside. Support the light assembly from outside if possible to prevent it from falling when last fastener is removed.
6. 6

   Remove third brake light assembly from exterior
   From outside the vehicle (use ladder or step stool if necessary), gently pull the third brake light assembly away from the roof. If resistance is felt, check for adhesive weatherstrip seal. Carefully use a plastic trim tool to release any remaining adhesive bond. Remove the assembly completely and bring inside for inspection.
7. 7

   Inspect and clean mounting area
   Inspect the roof opening and mounting surface for damage, corrosion, or water intrusion evidence. Clean the mounting surface thoroughly with isopropyl alcohol to ensure proper seal of new assembly. Check that no debris has fallen into roof cavity. Inspect wiring harness for damage or chafing.
8. 8

   Prepare new third brake light assembly
   Remove new third brake light from packaging and compare with old unit to verify correct part. If weatherstrip seal is separate, install it onto the new light assembly according to manufacturer instructions. Ensure seal is properly seated in all mounting channels without gaps or twists.
9. 9

   Install new third brake light assembly
   From outside the vehicle, position the new third brake light assembly into the roof opening. Align mounting holes with studs or threaded inserts. Ensure weatherstrip seal contacts roof surface evenly around entire perimeter. Press assembly firmly into place but do not fully seat until fasteners are started.
10. 10

    Secure mounting fasteners
    From inside cargo area, thread on mounting nuts or install mounting screws. Start all fasteners by hand before tightening any. Tighten fasteners in a cross-pattern to ensure even pressure and proper seal. Tighten to snug specification (hand tight plus 1/4 turn for 10mm nuts). Do not overtighten as this may crack the light housing.
11. 11

    Connect electrical connector
    Connect the electrical connector to the new third brake light assembly. Ensure connector is fully seated and audible/tactile click is felt. Engage any secondary locking tabs. Gently tug on connector to verify secure connection. Route wiring to prevent pinching during headliner reinstallation.
12. 12

    Reinstall headliner panel
    Raise the headliner panel back into position, aligning with marked reference points. Install all T20 Torx screws and push-pin fasteners in reverse order of removal. Ensure panel edges are flush and gaps are even. Reconnect and reinstall rear cargo LED light assemblies.
13. 13

    Reconnect battery and initialize system
    Reconnect the 12V auxiliary battery negative terminal. Enter vehicle and turn on ignition without engaging drive mode. The vehicle may display warning messages during system initialization. Allow all vehicle systems to complete self-checks (approximately 2-3 minutes).

Reassembly

1. Verify all interior trim panels are properly secured with no loose fasteners or rattles
2. Ensure headliner is flush and properly aligned with no sagging or gaps
3. Confirm no tools or parts have been left in cargo area or roof cavity
4. Check that all cargo area lighting functions properly after reassembly

Verification

• With ignition on, press brake pedal and verify third brake light illuminates brightly with no flickering or dark spots
• Release brake pedal and verify third brake light turns completely off with no residual glow
• Have an assistant observe from behind while you apply brakes multiple times to confirm proper operation
• If available, use multimeter to verify proper voltage at third brake light (12V DC when brake applied, 0V when released)
• Inspect exterior mounting area for proper seal and alignment - no gaps should be visible around weatherstrip
• Check for any water leaks by spraying mounting area with water and inspecting from inside
• Perform a test drive and verify no warning lights or brake system messages appear on instrument cluster
• Confirm third brake light activates during regenerative braking events as well as friction brake application
• Document repair completion and advise operator that all safety lighting is functioning properly

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