Front Suspension Rebuild

Complete removal, inspection, and replacement of all front suspension components including control arms, struts, tie rods, ball joints, and bushings for the Rivian EDV 500 dual motor electric delivery van.

Warnings

Tools required

Parts

• Upper control arm (left) × 1 — Use OEM specification
• Upper control arm (right) × 1 — Use OEM specification
• Lower control arm (left) × 1 — Use OEM specification
• Lower control arm (right) × 1 — Use OEM specification
• Front strut assembly (left) × 1 — Use OEM specification
• Front strut assembly (right) × 1 — Use OEM specification
• Tie rod end outer (left) × 1 — Use OEM specification
• Tie rod end outer (right) × 1 — Use OEM specification
• Sway bar end link (left) × 1 — Use OEM specification
• Sway bar end link (right) × 1 — Use OEM specification
• Upper ball joint (left) × 1 — Use OEM specification
• Upper ball joint (right) × 1 — Use OEM specification
• Lower ball joint (left) × 1 — Use OEM specification
• Lower ball joint (right) × 1 — Use OEM specification
• Control arm bushing kit × 1 — Use OEM specification
• Strut mount bearing assembly × 2 — Use OEM specification
• Hardware kit (nuts, bolts, cotter pins) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes for system capacitors to discharge
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Raise front of vehicle using manufacturer lift points and support on jack stands rated for vehicle weight
6. Remove both front wheels completely
7. Spray all suspension fasteners with penetrating oil and allow to soak for 15-30 minutes
8. Photograph or mark suspension geometry and ride height sensor positions for reference
9. Disconnect any ABS wheel speed sensor connectors and secure wiring away from work area

Procedure

1. 1

   Remove sway bar end links
   Remove the sway bar end links from both sides. Hold the ball stud with a wrench while loosening the retaining nut. Remove upper attachment to strut and lower attachment to sway bar. Inspect sway bar bushings for wear while accessible.
2. 2

   Disconnect tie rod ends from steering knuckles
   Remove cotter pins from tie rod end castle nuts. Loosen but do not fully remove castle nuts (leave 2-3 threads engaged). Use tie rod end puller to separate taper from steering knuckle. Once taper releases, remove castle nut completely and extract tie rod end. Mark thread position on inner tie rod for approximate alignment reference.
3. 3

   Disconnect brake caliper and rotor
   Remove brake caliper mounting bolts and support caliper with wire or bungee cord (do not let it hang by brake hose). Remove caliper bracket if necessary for clearance. Remove rotor retaining screws if present and slide rotor off hub. This provides access to hub and suspension components.
   ⚠Never let brake caliper hang by the brake hose as this can damage the hose internally.
4. 4

   Separate upper ball joint from knuckle
   Remove upper ball joint castle nut and cotter pin. Use ball joint separator to break taper connection between upper control arm ball joint and steering knuckle. Apply force to separator tool gradually to avoid damaging threads. Once separated, remove any remaining fasteners.
   ⚠Ball joint separators can slip under load. Wear eye protection and keep hands clear of pinch points.
5. 5

   Separate lower ball joint from knuckle
   Remove lower ball joint pinch bolt or castle nut (depending on design). Use ball joint separator or pickle fork to break taper between lower control arm and steering knuckle. The knuckle assembly should now be free from control arms. Support knuckle and hub assembly to prevent it from falling.
6. 6

   Remove strut upper mounting nuts
   Access strut tower from under hood. Disconnect any height sensor or damping control connectors at strut tower. Remove strut upper mounting nuts (typically 3-4 nuts) while supporting strut assembly from below. Do not allow strut to drop suddenly.
   ⚠Strut assemblies are heavy (40-50 lbs each). Have an assistant support the strut or use a transmission jack during removal.
7. 7

   Remove strut lower mounting bolts
   Remove bolts connecting strut assembly to steering knuckle or lower control arm (design dependent). Carefully lower strut assembly from vehicle. Repeat for opposite side. Place strut assemblies on bench for disassembly.
8. 8

   Disassemble strut assemblies
   Using spring compressor, carefully compress coil spring until upper strut mount is loose. Hold center strut shaft with appropriate tool and remove top nut. Carefully remove upper mount, bearing plate, spring seat, and compressed spring. Inspect all components for wear. Replace strut cartridge, mounts, and springs as needed.
   ⚠️Compressed springs can cause severe injury if released suddenly. Ensure spring compressor is properly engaged before loosening strut shaft nut. Wear face shield.
9. 9

   Remove upper control arms
   Remove bolts connecting upper control arm to frame or crossmember (typically at front and rear pivot points). Note position of any alignment shims or eccentric cams. Remove upper control arm from vehicle. If replacing bushings only, press out old bushings and press in new ones ensuring proper orientation. Repeat for opposite side.
10. 10

    Remove lower control arms
    Support lower control arm with floor jack. Remove bolts connecting lower control arm to frame or subframe (typically front and rear mounting points). Carefully lower control arm from vehicle. If replacing bushings only, use hydraulic press with proper adapters to remove and install bushings. Ensure bushings are pressed to correct depth. Repeat for opposite side.
11. 11

    Install new lower control arms
    Position new or rebuilt lower control arms into mounting locations. Install bolts loosely at both front and rear pivot points. Do not fully tighten suspension pivot bolts until vehicle is at ride height with weight on suspension. Repeat for both sides.
12. 12

    Install new upper control arms
    Position new or rebuilt upper control arms to frame mounting points. Install mounting bolts loosely. Transfer any alignment shims or eccentric cams from old control arms to match previous settings as closely as possible. Do not fully tighten until vehicle is at ride height. Repeat for both sides.
13. 13

    Reassemble and install strut assemblies
    Install new strut mount bearings, upper mount, and spring seats onto new strut cartridges. Using spring compressor, carefully compress new coil springs and install onto strut. Align spring ends with seats. Install upper mount assembly and torque center shaft nut per specification (typically 35-50 ft-lbs). Slowly release spring compressor. Position assembled strut into vehicle and install upper mounting nuts finger-tight.
14. 14

    Connect strut lower mounts and knuckle
    Align strut lower mount with steering knuckle or control arm mounting point. Install lower strut bolts and tighten according to specification. Connect upper and lower ball joints to steering knuckle. Install castle nuts and torque to specification. Install new cotter pins. Ensure ball joint tapers are fully seated.
15. 15

    Install tie rod ends and sway bar links
    Thread new tie rod ends onto inner tie rods to match marked position from disassembly. Insert tie rod end taper into steering knuckle. Install castle nut and torque to specification (typically 35-45 ft-lbs). Install new cotter pin. Install sway bar end links connecting sway bar to struts/control arms. Torque all fasteners to specification.
16. 16

    Reinstall brake components and wheels
    Reinstall brake rotors and caliper brackets. Install brake calipers and torque mounting bolts to specification. Reconnect ABS wheel speed sensors and any height sensor connectors. Install wheels and torque lug nuts in star pattern to specification (typically 130-150 ft-lbs for this vehicle).
17. 17

    Lower vehicle and torque suspension pivots
    Carefully lower vehicle until suspension is at normal ride height but jack stands still provide safety support. Torque all suspension pivot bolts (control arm mounting bolts, strut top nuts) to specification while vehicle is at ride height. This is critical for bushing longevity. Once all fasteners are torqued, fully lower vehicle and remove jack stands.
    ℹ️Suspension pivot bolts must be torqued at ride height to prevent bushing bind and premature wear.

Reassembly

1. Reconnect 12V auxiliary battery negative terminal
2. Pump brake pedal several times to restore brake pedal firmness before moving vehicle
3. Check all fasteners for proper torque and installation of all cotter pins/lock tabs
4. Verify all electrical connectors (ABS sensors, height sensors) are properly reconnected
5. Test drive vehicle at low speed in safe area to verify no unusual noises or handling issues

Verification

• Perform complete visual inspection of all installed components for proper seating and clearance
• Verify no suspension components contact frame, body, or brake lines during full steering lock and suspension travel
• Check that all castle nuts have properly installed cotter pins
• Confirm brake pedal is firm and brake system functions properly before road test
• Schedule four-wheel alignment immediately - vehicle is not safe for highway speeds until aligned
• After alignment, test drive and verify straight-line tracking, no pulls, and proper steering return to center
• Re-torque wheel lug nuts after 50-100 miles of driving
• Inspect all suspension fasteners and check torque after 500 miles of driving

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