This procedure covers the removal and replacement of both upper and lower ball joints on the front suspension of the 2022 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Upper ball joint × 2 — Use OEM specification
• Lower ball joint × 2 — Use OEM specification
• Upper ball joint castle nut × 2 — Use OEM specification
• Lower ball joint castle nut × 2 — Use OEM specification
• Cotter pins × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal and secure away from terminal post
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Raise front of vehicle using floor jack at designated front lift point
6. Support vehicle with jack stands at manufacturer-specified support points on frame rails
7. Remove front wheels completely and set aside
8. Spray all ball joint fasteners, control arm bolts, and castle nuts with rust penetrant and allow to soak for 15-20 minutes

Procedure

1. 1

   Remove brake caliper and rotor
   Remove brake caliper mounting bolts and suspend caliper with wire or bungee cord to avoid stressing brake hose. Do not let caliper hang by brake line. Remove brake rotor to gain clear access to suspension components.
2. 2

   Disconnect steering knuckle from tie rod end
   Remove cotter pin from tie rod end castle nut. Remove castle nut. Use tie rod separator tool or pickle fork to separate tie rod end from steering knuckle. Be careful not to damage tie rod end boot if reusing components.
3. 3

   Remove upper ball joint cotter pin and castle nut
   Locate upper ball joint at top of steering knuckle where it connects to upper control arm. Remove and discard cotter pin. Using appropriate socket, remove castle nut from upper ball joint stud. Do not fully separate joint yet.
4. 4

   Remove lower ball joint cotter pin and castle nut
   Locate lower ball joint at bottom of steering knuckle where it connects to lower control arm. Remove and discard cotter pin. Remove castle nut from lower ball joint stud. Keep tension on knuckle assembly as it may drop when separated.
   ⚠Support the steering knuckle/hub assembly before fully separating ball joints to prevent it from falling and causing injury or component damage.
5. 5

   Separate ball joints from steering knuckle
   Use ball joint separator or pickle fork to separate upper ball joint taper from knuckle. Support the knuckle assembly. Separate lower ball joint from knuckle using the same method. Carefully remove steering knuckle assembly and set aside on clean work surface.
6. 6

   Remove upper ball joint from upper control arm
   If ball joint is press-fit: Position control arm in ball joint press with proper adapters supporting control arm around ball joint. Press old ball joint out of control arm bore. If ball joint is bolted: Remove mounting bolts and extract ball joint from control arm. Clean the bore thoroughly with wire brush.
   ⚠Ensure ball joint press adapters are properly sized and positioned to avoid damaging control arm during press operation.
7. 7

   Remove lower ball joint from lower control arm
   Position lower control arm in ball joint press with proper adapters supporting control arm around ball joint. Press old ball joint out of control arm bore. Alternatively, if bolted design, remove mounting bolts and extract ball joint. Clean the bore and inspect for cracks or damage.
8. 8

   Install new lower ball joint
   Position new lower ball joint in control arm bore ensuring proper orientation (grease fitting accessible). Use ball joint press with appropriate adapters to press new ball joint fully into control arm until seated. Verify ball joint is fully seated and sits flush or to specification. If bolted design, install with new hardware and torque to specification.
9. 9

   Install new upper ball joint
   Position new upper ball joint in upper control arm bore with correct orientation. Press ball joint into control arm using proper press adapters until fully seated against control arm. Ensure even seating around entire circumference. If bolted design, install with new hardware and torque per specification.
10. 10

    Reinstall steering knuckle assembly
    Lift steering knuckle/hub assembly into position. Insert lower ball joint stud into knuckle. Install new lower castle nut and tighten until snug. Insert upper ball joint stud into knuckle. Install new upper castle nut and tighten until snug. Do not torque yet.
11. 11

    Torque ball joint castle nuts
    Torque lower ball joint castle nut to manufacturer specification. Continue tightening only as needed to align castle nut slots with ball joint stud hole for cotter pin installation (do not back off). Install new cotter pin and bend ends to secure. Repeat process for upper ball joint castle nut and cotter pin. Note: Torque specifications are not available in database - refer to Rivian service manual for exact values.
12. 12

    Reconnect tie rod end
    Insert tie rod end stud into steering knuckle. Install castle nut and torque to specification. Align castle nut slots with stud hole and install new cotter pin. Bend cotter pin ends to secure.
13. 13

    Reinstall brake rotor and caliper
    Install brake rotor onto hub. Reinstall brake caliper into position and install caliper mounting bolts. Torque caliper bolts to specification. Ensure brake hose is not twisted or kinked.
14. 14

    Repeat for opposite side
    Perform steps 1 through 13 on the opposite side of the vehicle to replace both upper and lower ball joints. Maintain consistent procedures and torque specifications.
15. 15

    Reinstall wheels and lower vehicle
    Install front wheels and hand-tighten lug nuts in star pattern. Lower vehicle until wheels contact ground but vehicle weight is not fully on suspension. Torque lug nuts to specification in star pattern. Fully lower vehicle and remove jack stands. Reconnect 12V battery negative terminal.

Reassembly

1. Ensure all cotter pins are properly installed and bent to prevent castle nut loosening
2. Verify all suspension fasteners are torqued to specification using Rivian service manual
3. Check that brake calipers are properly secured and brake hoses are not twisted
4. Pump brake pedal several times to ensure proper brake caliper piston positioning

Verification

• Before driving, turn steering wheel lock to lock while stationary and listen for any binding or unusual noises from ball joints
• Perform a visual inspection of all installed components to verify proper seating and fastener installation
• Test drive vehicle at low speed in a safe area and verify steering response and suspension operation
• Schedule four-wheel alignment immediately after repair - ball joint replacement requires alignment to prevent tire wear and ensure proper handling
• After 50-100 miles, re-torque all suspension fasteners and verify cotter pins remain secure
• Inspect ball joint boots for proper seating and absence of tears or damage

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