This procedure covers the removal and replacement of both front strut assemblies on a 2022 Rivian EDV 500 commercial delivery van, including suspension disconnection and wheel alignment requirements.

Warnings

Tools required

Parts

• Front strut assembly - left × 1 — Use OEM specification
• Front strut assembly - right × 1 — Use OEM specification
• Strut top mount nuts × 6 — Use OEM specification
• Strut-to-knuckle pinch bolt and nut × 2 — Use OEM specification
• Sway bar end link nuts (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake firmly
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery (located in front compartment) to prevent electrical issues during service
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Apply penetrating oil to all visible suspension fasteners and allow to soak for 30+ minutes
6. Raise front of vehicle using floor jack at designated front lift points per owner's manual
7. Support vehicle with jack stands rated for EV weight at frame rail positions - never rely solely on jack
8. Remove front wheels completely and set aside
9. Photograph or mark alignment cam positions if present for reference during reassembly

Procedure

1. 1

   Access and mark strut top mounts
   Open front hood/service panel to access strut tower mounting points in engine bay. Identify the three strut top mount nuts for each side. Mark or photograph the position of any alignment washers or cams. Clean area around mounts to prevent debris from falling into strut tower during removal.
2. 2

   Disconnect front brake line bracket
   Locate the brake line bracket attached to the strut body. Remove the mounting bolt securing the brake line bracket to the strut. Gently move brake line aside and secure with wire or zip-tie to prevent strain on brake hose during strut removal. Do not disconnect brake line from caliper or allow brake line to hang unsupported.
3. 3

   Disconnect ABS wheel speed sensor wiring
   Locate the ABS wheel speed sensor wire routing along the strut or attached to the steering knuckle. Disconnect the electrical connector and unclip any wire routing brackets from the strut body. Secure wiring away from work area to prevent damage.
4. 4

   Disconnect sway bar end link from strut
   Locate the sway bar end link attachment point on the strut body. Use appropriate size socket and wrench to hold the end link stud while removing the top nut connecting end link to strut. Use penetrating oil if fastener is seized. Allow end link to hang from sway bar - do not remove completely from vehicle.
5. 5

   Remove strut-to-knuckle pinch bolt
   Locate the large pinch bolt securing the bottom of the strut to the steering knuckle (typical Rivian design uses a pinch clamp arrangement). Note the orientation and any alignment markings on the knuckle-to-strut interface. Remove the pinch bolt and nut completely. The strut shaft may be press-fit into the knuckle - do not force separation yet.
6. 6

   Separate strut from steering knuckle
   Using a pry bar or appropriate tool, carefully spread the pinch clamp opening on the steering knuckle to release the strut shaft. Support the strut assembly from below to prevent it from falling. Apply gentle leverage while pulling outward on the strut - if extremely tight, tap gently with a rubber mallet on the knuckle ears while prying. Avoid damaging knuckle or strut shaft surfaces.
7. 7

   Support and remove strut top mount nuts
   With the strut bottom disconnected, position yourself in the engine bay with access to strut tower. Have an assistant support the strut assembly from below, or use a suitable support stand. Remove the three top mount nuts securing the strut to the strut tower. Hold the center strut shaft if it begins to rotate (use appropriate tool if provided). Lower the strut assembly carefully from the wheel well.
8. 8

   Remove first strut assembly
   Carefully maneuver the strut assembly out through the wheel well opening, tilting as necessary to clear brake components and suspension geometry. Inspect the removed strut for any signs of leaking fluid, damaged mounting bushings, or spring damage. Set aside in safe location.
9. 9

   Repeat removal for opposite side
   Perform steps 2 through 8 on the opposite side front strut assembly. Remove brake line bracket, ABS sensor wiring, sway bar end link connection, pinch bolt, separate from knuckle, and remove top mount nuts. Extract second strut assembly through wheel well.
10. 10

    Inspect strut towers and knuckle bores
    With both struts removed, inspect strut tower mounting surfaces for rust, damage, or deformation. Clean mounting surfaces with wire brush if necessary. Inspect steering knuckle pinch clamp bores for damage, cracks, or deformation. Clean the knuckle bore areas thoroughly to ensure new struts seat properly.
11. 11

    Install first new strut assembly into strut tower
    Lift new strut assembly into position through wheel well, aligning the top mount studs with strut tower holes. Guide carefully to avoid damaging threads. Once studs protrude through tower, thread top mount nuts onto studs by hand - do not fully tighten yet. Ensure strut orientation matches original installation with any orientation markings properly positioned.
12. 12

    Insert strut shaft into steering knuckle
    Guide the bottom strut shaft into the steering knuckle pinch clamp bore. Ensure shaft is fully seated to the depth marks if present. Align the pinch clamp bolt hole. The fit should be snug but not require excessive force. Rotate the strut as needed to achieve proper alignment with all connection points. Install pinch bolt and nut but do not fully tighten yet.
13. 13

    Reconnect sway bar end link and brackets
    Reconnect the sway bar end link to the strut mounting point. Thread nut onto end link stud but do not fully tighten yet. Reconnect brake line bracket to strut body with mounting bolt. Reconnect ABS wheel speed sensor wiring and secure all wire routing clips to strut body in original positions.
14. 14

    Install second strut assembly
    Repeat steps 11 through 13 for the opposite side front strut. Install strut into tower with top mount nuts hand-tight, insert shaft into knuckle and install pinch bolt, then reconnect sway bar end link, brake line bracket, and ABS sensor wiring. Verify both sides are properly positioned before final torquing.
15. 15

    Final torque all fasteners to specification
    With vehicle still supported on jack stands and suspension hanging, torque all fasteners in the following order per Rivian specifications (consult factory service manual for exact values as none are provided in this database): (1) Strut top mount nuts - typically 18-22 ft-lbs in star pattern, (2) Strut-to-knuckle pinch bolt - typically 70-85 ft-lbs, (3) Sway bar end link nuts - typically 35-45 ft-lbs, (4) Brake line bracket bolt - typically 18-22 ft-lbs. Double-check all connections are secure.

Reassembly

1. Reinstall front wheels and hand-tighten lug nuts in star pattern
2. Carefully lower vehicle from jack stands to ground using floor jack
3. With vehicle weight on ground, torque wheel lug nuts to Rivian specification (typically 120-130 ft-lbs) in star pattern
4. Reconnect 12V auxiliary battery
5. Remove wheel chocks
6. Verify all tools and parts have been removed from under vehicle and engine bay

Verification

• Start vehicle and verify no warning lights appear on instrument cluster related to ABS or suspension systems
• Perform slow-speed test drive in safe area (parking lot) and verify no unusual noises, pulling, or vibration from front suspension
• Visually inspect all connection points for proper seating and torque
• Schedule professional four-wheel alignment immediately - vehicle is not safe for highway speeds until alignment is verified within specification
• After alignment, test drive at various speeds and verify proper steering response and handling characteristics
• Re-torque all fasteners after 50-100 miles of driving as suspension settles

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