This procedure covers the removal and replacement of the front upper control arm bushings on a 2022 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Front upper control arm bushing × 2 — Use OEM specification
• Upper ball joint nut (if damaged) × 2 — Use OEM specification
• Control arm mounting hardware (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal to prevent electrical issues during repair
4. Loosen front wheel lug nuts while vehicle is on ground
5. Raise front of vehicle with floor jack at manufacturer-specified lift points
6. Support vehicle securely on jack stands placed at proper frame support points
7. Remove both front wheels completely
8. Spray all suspension fasteners with penetrating oil and allow to soak for 15-30 minutes

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm to support the suspension assembly. Raise jack just enough to take slight load off the upper control arm, preventing the suspension from dropping when disconnected. This keeps tension off components during disassembly.
2. 2

   Remove upper ball joint from knuckle
   Locate the upper ball joint castle nut where the upper control arm connects to the steering knuckle. Remove the cotter pin if equipped. Using appropriate socket, remove the upper ball joint nut completely. Use a ball joint separator tool or pickle fork to separate the ball joint taper from the knuckle. Tap the separator tool with a hammer until the joint releases. Avoid damaging the ball joint boot if reusing the control arm.
   ⚠The suspension will shift when the ball joint is separated. Ensure the floor jack is properly supporting the lower control arm.
3. 3

   Mark control arm orientation
   Before removing the control arm, use paint or a marker to mark the orientation of the control arm relative to the frame mounting points. This ensures proper reinstallation alignment and reduces alignment adjustment time later.
4. 4

   Remove control arm frame mounting bolts
   Locate the two bolts securing the upper control arm to the frame mounting brackets. These are typically located at the front and rear of the control arm. Using a breaker bar and appropriate socket, remove both mounting bolts. Note the orientation of any eccentric washers or cam bolts used for alignment adjustment. Keep all hardware organized for reassembly.
5. 5

   Remove control arm from vehicle
   With all mounting hardware removed and ball joint disconnected, carefully remove the upper control arm from the vehicle. Inspect the ball joint, mounting points, and surrounding components for wear or damage. Clean the frame mounting areas with a wire brush to remove rust and debris.
6. 6

   Press out old bushings
   Secure the control arm in a hydraulic press or bench vise with press attachment. Using the appropriate size bushing press adapters, carefully press out the old bushings from the control arm. Work slowly and ensure the press adapters are properly aligned to avoid damaging the control arm. Inspect the bushing bore for damage, cracks, or excessive wear.
   ⚠Wear safety glasses during pressing operations. Metal fragments can be ejected under pressure.
7. 7

   Clean bushing bores
   Thoroughly clean the bushing bores in the control arm using a wire brush and appropriate solvent. Remove all old rubber residue, corrosion, and debris. Inspect bores for damage. The bores must be clean and smooth for proper new bushing installation.
8. 8

   Press in new bushings
   Position new bushings in control arm bores, ensuring proper orientation as marked on the bushing or per manufacturer specifications. Apply light coating of silicone grease to bushing outer diameter if specified. Using hydraulic press with proper adapters, carefully press new bushings into place until fully seated. Ensure bushings are pressed straight and are fully bottomed in their bores. Do not over-press as this can damage the bushings.
   ℹ️Some bushings have directional orientation. Verify correct positioning before pressing.
9. 9

   Reinstall control arm to frame
   Position the control arm back into the frame mounting brackets, aligning with the orientation marks made during disassembly. Insert the mounting bolts through the bushings and frame brackets. Install any eccentric washers or cam bolts in their original positions. Thread nuts onto bolts but do not fully tighten yet. Suspension bushings must be torqued at ride height.
10. 10

    Reconnect ball joint to knuckle
    Swing the steering knuckle into position and align the upper ball joint stud with the hole in the knuckle. You may need to carefully adjust the floor jack height under the lower control arm to align the components. Insert the ball joint stud through the knuckle and install the castle nut. Tighten the nut and install a new cotter pin if applicable.
11. 11

    Torque all fasteners at ride height
    Lower the vehicle until the suspension is at normal ride height (wheels just touching ground or on ramps). This ensures bushings are torqued in their normal operating position, preventing premature wear. Torque the upper control arm frame mounting bolts to factory specification. Torque the upper ball joint nut to specification. Consult Rivian service documentation for all torque values as none are available in this database.
    ⚠Torquing suspension bushings while the suspension is hanging can cause binding and premature bushing failure.
12. 12

    Repeat for opposite side
    Perform steps 1-11 for the opposite side front upper control arm bushing. Both sides should be serviced to maintain balanced suspension performance and alignment characteristics.

Reassembly

1. Reinstall both front wheels and hand-tighten lug nuts
2. Carefully lower vehicle completely to ground
3. Torque wheel lug nuts to specification in star pattern
4. Reconnect 12V battery negative terminal
5. Remove wheel chocks

Verification

• Test drive vehicle at low speed in a safe area to verify no unusual noises or handling issues
• Check that steering returns to center normally and there is no binding in suspension travel
• Verify no new rattles or clunks over bumps
• Schedule four-wheel alignment immediately after repair - improper alignment can cause tire wear and handling problems
• After alignment, recheck all fastener torque values
• Inspect repair area after 50-100 miles for any loosening or issues

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