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

Warnings

Tools required

Parts

• Upper ball joint × 1 — Use OEM Rivian specification
• Upper control arm to ball joint mounting hardware × 1 — Use OEM specification
• Cotter pin or castle nut lock × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery negative terminal
4. If equipped with air suspension, use service mode to deflate suspension system
5. Loosen wheel lug nuts while vehicle is on ground
6. Raise vehicle and support securely on jack stands at manufacturer-specified lift points
7. Remove wheel and tire assembly
8. Spray all suspension fasteners with penetrating oil and allow to soak

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm to support the suspension assembly. Raise jack until it just makes contact and takes slight load, but does not lift the vehicle. This prevents the suspension from dropping when the upper ball joint is disconnected.
2. 2

   Disconnect wheel speed sensor
   Locate the wheel speed sensor wire harness on the upper control arm or knuckle area. Disconnect the electrical connector and carefully unclip any wire harness retainers to provide clearance for ball joint removal.
3. 3

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and secure the caliper to the chassis with mechanic's wire to prevent strain on the brake hose. Remove the brake rotor to provide access to the upper ball joint area. Do not let the caliper hang by the brake hose.
4. 4

   Separate upper ball joint from steering knuckle
   Remove the castle nut or retaining nut securing the upper ball joint stud to the steering knuckle. Remove any cotter pin first if equipped. Use a ball joint separator tool or pickle fork to break the taper connection between the ball joint stud and knuckle. Apply force gradually to avoid damaging the steering knuckle or surrounding components.
5. 5

   Remove upper control arm mounting bolts
   Support the upper control arm by hand or with an additional support. Remove the bolts securing the upper control arm to the chassis or suspension tower. Note the position and orientation of any alignment shims or eccentric washers for reinstallation. Carefully lower the control arm assembly.
6. 6

   Remove ball joint from control arm
   Secure the upper control arm in a bench vise. Identify whether the ball joint is riveted, bolted, or pressed into the control arm. If riveted, drill out the rivets using a drill bit slightly larger than the rivet shaft, being careful not to damage the control arm. If pressed, use a ball joint press with appropriate adapters to press the old ball joint out of the control arm bore.
7. 7

   Clean control arm bore
   Use a wire brush to thoroughly clean the ball joint mounting bore in the control arm. Remove all rust, debris, and old paint. Inspect the bore for cracks, elongation, or damage. Replace the control arm if the bore is damaged or worn beyond specification.
8. 8

   Install new ball joint
   Position the new ball joint in the control arm bore with the correct orientation (stud facing outward). Use the ball joint press with appropriate receiving cup and driver to press the new ball joint into the control arm until it is fully seated. Ensure the ball joint is pressed in straight and bottoms out completely in the bore. If the new ball joint has bolt holes instead of a press fit, align the holes and install the new bolts per OEM specifications.
9. 9

   Reinstall upper control arm
   Position the upper control arm back into its mounting location. Install any alignment shims or eccentric washers in their original positions. Thread in the control arm mounting bolts finger-tight. Do not fully torque at this time as suspension should be at ride height for final torquing.
10. 10

    Connect ball joint to steering knuckle
    Guide the ball joint stud into the steering knuckle taper hole. Install the castle nut or retaining nut and tighten to draw the taper connection tight. Ensure the ball joint stud is fully seated in the knuckle before final torquing. Install new cotter pin if equipped, or lock mechanism per OEM design.
11. 11

    Reinstall brake components
    Reinstall the brake rotor onto the hub. Position the brake caliper over the rotor and install the caliper mounting bolts. Reconnect the wheel speed sensor harness and secure all wire retaining clips.
12. 12

    Lower suspension to ride height
    Carefully lower the floor jack supporting the lower control arm until the suspension is at normal ride height (weight on wheels). At this position, torque all control arm mounting bolts and ball joint castle nut to manufacturer specifications. Note: Torque specifications are not available in the database; consult Rivian service information for proper values.

Reassembly

1. Install wheel and tire assembly, torquing lug nuts in a star pattern to manufacturer specification
2. Remove jack stands and carefully lower vehicle to ground
3. Perform final torque check on lug nuts with vehicle on ground
4. Reconnect 12V auxiliary battery negative terminal
5. If equipped with air suspension, exit service mode and allow system to re-inflate to normal ride height
6. Clear any suspension-related fault codes using appropriate scan tool

Verification

• Perform visual inspection of all connections and ensure no fasteners were left loose
• Bounce each corner of the vehicle to verify suspension operates smoothly without binding or unusual noises
• Perform a slow-speed test drive in a safe area, listening for clunks, pops, or unusual suspension noises
• Verify steering wheel returns to center and vehicle tracks straight
• Schedule four-wheel alignment immediately, as suspension geometry has been altered
• After 50-100 miles of driving, re-torque all suspension fasteners and verify ball joint condition

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