This procedure covers removal and installation of the front steering knuckle/spindle assembly on the 2022 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Front steering knuckle assembly × 1 — Use OEM specification
• Front axle nut × 1 — Use OEM specification - single use
• Lower ball joint nut × 1 — Use OEM specification
• Upper ball joint nut × 1 — Use OEM specification
• Tie rod end nut × 1 — Use OEM specification
• Brake caliper mounting bolts × 2 — Use OEM specification if reusing
• ABS sensor O-ring × 1 — Use OEM specification
• Anti-seize compound × 1 — Copper or nickel based

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 2 minutes
3. Verify high-voltage system is safely de-energized following Rivian service procedures
4. Loosen front axle nut while vehicle is on ground (do not remove)
5. Raise vehicle using floor jack at designated front lift point
6. Support vehicle with jack stands rated for 10,000+ lbs at frame rails
7. Remove front wheel and tire assembly
8. Mark alignment reference points on control arms and frame if possible
9. Spray all fasteners with penetrating oil and allow to soak

Procedure

1. 1

   Remove brake caliper assembly
   Remove the two brake caliper mounting bolts from the back of the caliper bracket. Carefully lift the caliper and bracket assembly off the rotor. Support the caliper using a wire hanger or caliper hanger from the suspension or frame - do not allow it to hang by the brake hose. Inspect brake hose for damage.
2. 2

   Remove brake rotor
   If rotor is held by retaining screws, remove them. Slide the brake rotor off the hub. If rotor is seized, use penetrating oil and a soft hammer to tap around the hat section. Do not damage the hub surface or rotor mounting face if reusing components.
3. 3

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor connector near the knuckle or inner fender area. Disconnect the electrical connector by releasing the locking tab. Remove the sensor mounting bolt from the knuckle and carefully extract the sensor from the bore. Note the routing of the sensor wire for reinstallation.
4. 4

   Remove front axle nut
   With the vehicle supported on jack stands, remove the previously loosened front axle nut completely. This nut is typically torqued to 150+ ft-lbs and should be replaced with a new nut upon reassembly. Keep the nut as a torque reference if specifications are not available.
5. 5

   Separate tie rod end from knuckle
   Remove the tie rod end castle nut (remove cotter pin first if equipped). Use a ball joint separator or pickle fork to separate the tie rod end taper from the knuckle steering arm. Insert the separator between the tie rod and knuckle and strike firmly until taper releases. Avoid damaging the tie rod boot or threads.
6. 6

   Separate upper ball joint from knuckle
   Remove the upper ball joint nut (remove cotter pin if equipped). Use a ball joint separator to break the taper connection between the upper control arm ball joint and knuckle. Position the separator tool carefully to avoid damaging the ball joint boot. Support the knuckle as the joint releases.
7. 7

   Separate lower ball joint from knuckle
   Remove the lower ball joint nut (remove cotter pin if equipped). Use a ball joint separator to release the lower control arm ball joint from the knuckle. The knuckle assembly will become loose once this joint is separated. Have a helper support the knuckle or use a strap to prevent it from falling.
8. 8

   Remove CV axle from hub
   With all ball joints and tie rod disconnected, pull the knuckle assembly outward from the vehicle. The CV axle shaft should slide out of the hub bore. If the axle is stuck, use a plastic hammer to tap on the end of the shaft while pulling the knuckle outward, or use a hub puller from behind the hub. Be careful not to damage the CV joint boots or shaft splines.
9. 9

   Remove knuckle assembly
   Once the CV axle is clear of the hub, remove the entire knuckle/spindle assembly from the vehicle. Inspect all mounting surfaces, ball joint tapers, and the hub bore for damage, corrosion, or wear. Clean all mating surfaces with a wire brush if reusing components.
10. 10

    Prepare new knuckle for installation
    If installing a new knuckle, verify it matches the original. Clean the hub bore and apply a thin coat of anti-seize to the CV axle splines (avoid getting anti-seize on the hub face). Install a new ABS sensor O-ring if equipped. Clean all ball joint taper seats thoroughly.
11. 11

    Install knuckle onto CV axle
    Align the new or cleaned knuckle assembly with the CV axle shaft. Slide the hub bore onto the axle shaft splines, ensuring proper engagement. The axle should pass completely through the hub. If resistance is encountered, verify splines are aligned and hub bore is clean.
12. 12

    Connect ball joints and tie rod
    Position the knuckle to align with the upper and lower ball joints and tie rod end. Install all three components into their respective taper seats on the knuckle. Start all three nuts by hand to hold the assembly in position. Do not fully tighten at this stage.
13. 13

    Torque suspension connections
    Torque the lower ball joint nut, upper ball joint nut, and tie rod end nut to manufacturer specifications. Without factory specifications available, typical values are 75-90 ft-lbs for ball joints and 50-75 ft-lbs for tie rod ends. Install new cotter pins if equipped, advancing nuts only to align pin holes (never back off). Thread a new axle nut onto the CV shaft finger-tight.
14. 14

    Install ABS sensor and brake components
    Insert the ABS wheel speed sensor into the knuckle bore with new O-ring installed. Torque the sensor bolt to specification (typically 8-12 ft-lbs). Route the sensor wire in the original position and connect the electrical connector. Install the brake rotor onto the hub, then mount the brake caliper and bracket assembly. Torque caliper mounting bolts to specification.
15. 15

    Final torque axle nut
    Install the wheel and tire assembly and hand-tighten lug nuts. Lower the vehicle to the ground so the full weight is on the suspension. Torque the front axle nut to manufacturer specification (typically 150-200+ ft-lbs for heavy electric vehicles). Stake or install cotter pin as required by design. Torque wheel lug nuts to specification in a star pattern.

Reassembly

1. All fasteners should be torqued to manufacturer specifications using a calibrated torque wrench
2. Replace all single-use fasteners including axle nut, cotter pins, and any lock nuts
3. Verify all electrical connectors are fully seated and locked
4. Ensure brake caliper is properly secured and brake hose has no kinks or tension

Verification

• Reconnect 12V battery and verify no warning lights appear on dash
• Test ABS sensor function using diagnostic scanner if available
• Check that wheel rotates freely without binding or unusual noise
• Pump brake pedal several times and verify firm pedal feel
• Perform a visual inspection of all connections and torqued fasteners
• Have vehicle aligned by qualified technician with proper Rivian alignment specifications
• Test drive vehicle at low speed in safe area and verify steering response and brake function before returning to service

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