This procedure covers the removal and replacement of the front coil springs on a 2022 Rivian EDV 500 electric delivery van, requiring suspension disassembly and use of a spring compressor.

Warnings

Tools required

Parts

• Front coil spring × 2 — Use OEM Rivian specification
• Upper strut mount bearing (if worn) × 2 — Inspect before ordering
• Strut mount hardware kit × 1 — Use OEM specification
• Lower control arm bushing (if damaged) × 2 — Inspect during disassembly

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Access vehicle settings through center display and enable Service Mode to disable high-voltage systems
4. Wait 5 minutes after enabling Service Mode for capacitors to discharge
5. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
6. Raise front of vehicle with floor jack at designated front lift points
7. Place jack stands under frame rails at proper support points, ensuring vehicle is stable
8. Remove front wheels completely and set aside
9. Spray all suspension fasteners with penetrating oil and allow to soak for 15-20 minutes
10. Photograph suspension assembly from multiple angles for reassembly reference
11. Inspect brake lines and ABS sensor wiring routing for clearance during disassembly

Procedure

1. 1

   Support lower control arm
   Position floor jack under the lower control arm as close to the ball joint as possible. Raise jack until it just contacts the control arm and takes slight load. This will support the suspension during disassembly and prevent sudden dropping when components are disconnected.
2. 2

   Disconnect upper strut mounting
   Open the hood and locate the upper strut mount access area. Remove the plastic cover or access panel if equipped. Identify the upper strut mount nuts (typically 3 nuts surrounding the center shaft nut). Do NOT remove the center shaft nut at this time. Remove only the perimeter mounting nuts that secure the strut assembly to the body. Support the strut assembly from below while removing the last nut.
3. 3

   Disconnect stabilizer bar link
   Locate the stabilizer bar end link connection to the strut assembly. Use a wrench to hold the link stud from rotating while removing the upper nut with another wrench. Disconnect the link from the strut. If ball joint is seized, use ball joint separator tool. Allow stabilizer bar to hang freely.
4. 4

   Remove brake caliper bracket
   Remove the brake caliper mounting bolts and carefully suspend the caliper assembly from the frame using wire or a bungee cord. Do not let caliper hang by the brake hose. Remove the brake caliper bracket mounting bolts and remove bracket. This provides clearance for strut removal.
5. 5

   Disconnect lower ball joint or strut-to-knuckle bolts
   Identify how the strut connects to the steering knuckle (may be pinch bolts through the knuckle or a separate lower control arm ball joint). If pinch bolts are used, remove them and spread the knuckle slightly with a pry bar to release the strut. If a ball joint connects the lower control arm, use a ball joint separator to disconnect it. Note the orientation of all components.
6. 6

   Remove strut assembly
   Carefully lower the floor jack supporting the control arm while guiding the strut assembly downward and out of the wheel well. The upper mount should pull free from the body. Maneuver the strut assembly clear of the vehicle and place on a clean work surface. Inspect all bushings and mounts for wear during removal.
7. 7

   Install spring compressor
   Install the coil spring compressor tool onto the coil spring, positioning the compression arms opposite each other (180 degrees apart) on the spring. Ensure compressor claws are properly seated in the coil grooves and centered. Install additional compressor sets if available for added safety (typically 2 sets total, 90 degrees apart). Verify all compressor components are secure before proceeding.
   ⚠️Verify spring compressor is properly rated and installed before tightening. Improper installation can cause catastrophic failure.
8. 8

   Compress coil spring
   Slowly and evenly tighten the spring compressor tools, alternating between compression points to maintain even pressure. Compress the spring until all tension is removed from the upper strut mount (you should be able to wiggle the mount freely). The spring should compress approximately 2-3 inches. Continuously verify compressor engagement as you tighten.
9. 9

   Remove upper mount and spring
   With spring fully compressed, use appropriate socket to hold the strut shaft from rotating while removing the upper mount center nut. Remove the upper mount assembly, bearing plate, and any isolators or spacers, noting their exact order and orientation. Carefully remove the compressed spring with compressors still attached. Remove the lower spring isolator from the strut.
10. 10

    Release old spring and prepare new spring
    Place the compressed old spring in a safe location. Slowly and evenly release tension on the spring compressors to fully decompress the old spring. Remove compressors from old spring. Inspect the new spring to ensure it matches the old spring specification. Install spring compressors on the new spring in the same configuration and compress to the same length as the old spring was compressed.
11. 11

    Install new spring and upper mount
    Install the lower spring isolator onto the strut body in its correct position. Place the compressed new spring onto the strut, ensuring the bottom coil is properly seated in the lower spring perch. Install any upper isolators, bearing plate, and upper mount assembly in the exact reverse order of removal, aligning any locating pins or tabs. Thread the upper mount nut onto the strut shaft and tighten while holding the shaft from rotating. Without factory specifications, tighten to typical specification of 45-55 ft-lb, but verify with Rivian documentation.
12. 12

    Release spring compressor
    Carefully and evenly release tension on the spring compressor tools, alternating between compression points. Ensure the spring seats properly in both the upper and lower perches as tension is released. Once spring is fully seated and supporting the assembly, remove all spring compressor tools.
    ⚠️Release spring compressor slowly and evenly. Watch for proper seating of spring in both perches.
13. 13

    Reinstall strut assembly
    Lift the strut assembly into position, guiding the upper mount studs through the body mounting holes. Install upper mount nuts finger-tight. Raise the floor jack under the lower control arm to align the strut with the steering knuckle. Reconnect the strut to the knuckle using original method (pinch bolts or ball joint). Without factory torque specifications, use typical values: pinch bolts 75-90 ft-lb, ball joint nuts 50-70 ft-lb, but verify with Rivian documentation.
14. 14

    Reconnect remaining components
    Reinstall the brake caliper bracket and brake caliper, torquing mounting bolts to specification (typically caliper bracket 85-100 ft-lb, caliper bolts 25-35 ft-lb). Reconnect the stabilizer bar end link to the strut. Tighten upper strut mount perimeter nuts in a star pattern to specification (typically 18-25 ft-lb). Remove floor jack from under control arm.
15. 15

    Install wheel and perform final checks
    Reinstall the wheel and hand-tighten lug nuts in a star pattern. Lower vehicle until wheel just contacts ground. Torque lug nuts to specification in a star pattern (verify Rivian specification, typically 140-150 ft-lb for commercial vehicles). Fully lower vehicle and remove jack stands. Repeat entire procedure for opposite side if replacing both springs.

Reassembly

1. Ensure all fasteners are tightened to proper specifications using a calibrated torque wrench
2. Verify brake system is properly reassembled and brake pedal is firm before driving
3. Reinstall any access panels or covers removed from strut tower area
4. Exit Service Mode through vehicle settings to re-enable high-voltage systems
5. Double-check that no tools or parts were left in wheel wells or engine compartment

Verification

• Bounce each corner of the vehicle to verify springs are properly seated and suspension operates normally without binding or unusual noises
• Perform a careful test drive at low speed in a safe area, listening for any suspension noises or irregular handling
• Check for any clearance issues between springs and other components during suspension travel
• Verify no warning lights or error codes are present on the instrument cluster
• Schedule a professional four-wheel alignment immediately, as suspension geometry has been disturbed
• Re-torque all fasteners after 50-100 miles of driving
• Monitor vehicle handling and tire wear patterns over the next several hundred miles

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