This procedure covers the removal and replacement of the lower ball joint on a 2022 Rivian EDV 500 electric delivery van with dual motor AWD.

Warnings

Tools required

Parts

• Lower ball joint × 1 — Use OEM Rivian specification
• Lower control arm (if ball joint not serviceable) × 1 — Use OEM Rivian specification
• Castle nut/castellated nut for ball joint × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 5 minutes
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support on jack stands at manufacturer-specified lift points
5. Remove front wheel on side being serviced
6. Spray all ball joint fasteners with penetrating oil and allow to soak
7. Place alignment turn plates under opposite wheel if available to prevent suspension binding

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the weight of the control arm and suspension. Raise jack just enough to slightly compress the suspension and relieve load from the ball joint.
2. 2

   Remove brake caliper
   Remove the brake caliper mounting bolts and carefully hang the caliper from the frame using a wire or bungee cord. Do not let caliper hang by the brake hose. Remove brake rotor if it interferes with access to lower ball joint.
3. 3

   Disconnect ABS wheel speed sensor
   Disconnect the ABS wheel speed sensor connector from the harness. Remove any routing clips that may interfere with lower control arm removal. Carefully move sensor wire out of work area.
4. 4

   Remove ball joint castle nut
   Remove the cotter pin from the lower ball joint castle nut using pliers or side cutters. Using a wrench or socket, remove the castle nut from the ball joint stud. Do not fully remove until the ball joint taper is broken.
5. 5

   Separate ball joint from steering knuckle
   Use a ball joint separator tool or pickle fork to break the taper between the ball joint stud and the steering knuckle. Position the tool between the control arm and knuckle, then strike with a hammer or use a hydraulic separator. The ball joint should pop free from the knuckle. If the castle nut is still installed, back it off until flush with the stud end to protect threads during separation.
   ⚠Wear eye protection when striking separation tools. The ball joint may separate suddenly.
6. 6

   Remove lower control arm bolts (if necessary)
   If the ball joint is pressed into the lower control arm and cannot be accessed in place, remove the lower control arm mounting bolts. Note the position and orientation of any alignment cams or adjustment hardware. Carefully lower the jack and remove the control arm from the vehicle.
7. 7

   Remove old ball joint
   Inspect whether the ball joint is bolted or pressed into the control arm. If bolted, remove the mounting bolts. If pressed, use a ball joint press kit or hydraulic press to press the old ball joint out of the control arm. Support the control arm properly in the press and use the correct size adapters to avoid damaging the control arm bore.
8. 8

   Clean control arm bore
   Use a wire brush to thoroughly clean the ball joint bore in the control arm. Remove any rust, debris, or old adhesive. Inspect the bore for damage, cracks, or excessive wear. If damage is present, the entire control arm must be replaced.
9. 9

   Install new ball joint
   Position the new ball joint into the control arm bore, ensuring correct orientation with the grease fitting (if equipped) facing the proper direction. Using the ball joint press with appropriate adapters, press the new ball joint into the control arm until it is fully seated. If the ball joint is bolt-in type, install with new bolts and tighten per manufacturer specification.
10. 10

    Reinstall lower control arm (if removed)
    Position the lower control arm back into the vehicle with the ball joint stud pointing toward the steering knuckle. Install control arm mounting bolts in their original positions, including any alignment cams or shims. Do not fully tighten at this stage - leave bolts snug to allow suspension to settle.
11. 11

    Connect ball joint to steering knuckle
    Raise the lower control arm using the floor jack to align the ball joint stud with the hole in the steering knuckle. Insert the stud through the knuckle. Install the new castle nut and tighten while ensuring the ball joint seats properly in the knuckle taper. Since torque specifications are not available, tighten to manufacturer specification when obtained, then install a new cotter pin through the castle nut slots and ball joint stud.
12. 12

    Final tighten control arm bolts
    With the vehicle weight supported on jack stands and suspension at normal ride height position, final tighten all lower control arm mounting bolts. This ensures proper bushing alignment and prevents premature wear.
13. 13

    Reinstall brake components
    Reinstall the brake rotor if removed. Mount the brake caliper back onto the caliper bracket and tighten mounting bolts. Reconnect the ABS wheel speed sensor connector and secure all wiring clips.
14. 14

    Reinstall wheel and lower vehicle
    Install the wheel and hand-tighten lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground. Torque lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.

Reassembly

1. Ensure all fasteners are tightened to proper specifications (obtain manufacturer torque values)
2. Verify cotter pin is properly installed through castle nut and bent to prevent removal
3. Reconnect 12V battery negative terminal
4. Pump brake pedal several times to ensure proper brake function before moving vehicle

Verification

• Test drive vehicle at low speed in a safe area and verify no unusual noises from suspension
• Check for proper steering response and no pulling to either side
• Visually inspect ball joint area for any fluid leaks or loose components
• Schedule four-wheel alignment as soon as possible - suspension geometry has been altered and tire wear will occur without proper alignment
• Re-torque all fasteners after 50-100 miles of driving
• Verify ABS system functions properly with no warning lights

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