Knuckle/Spindle - Rear

This procedure covers the removal and replacement of the rear knuckle/spindle assembly on a 2022 Rivian EDV 500 with dual motor AWD drivetrain.

Warnings

Tools required

Parts

• Rear knuckle/spindle assembly × 1 — Use OEM specification
• Wheel bearing hub assembly (if integrated) × 1 — Use OEM specification
• Lower control arm ball joint nut × 1 — Use OEM specification
• Upper control arm ball joint nut × 1 — Use OEM specification
• Tie rod end nut × 1 — Use OEM specification
• Brake caliper mounting bolts × 2 — Use OEM specification
• Axle hub nut × 1 — Use OEM specification
• ABS sensor (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 2 minutes
3. Disable high-voltage system following Rivian service procedures
4. Loosen rear axle hub nut while vehicle is still on ground
5. Raise and safely support vehicle on jack stands at manufacturer-specified lift points
6. Remove rear wheel and tire assembly
7. Spray all suspension fasteners with penetrating oil and allow to soak
8. Document or photograph suspension alignment for reference during reassembly

Procedure

1. 1

   Remove brake caliper assembly
   Remove the brake caliper mounting bolts and carefully lift the caliper off the rotor. Use wire or a caliper hanger to support the caliper from the suspension or frame without stressing the brake line. Do not let the caliper hang by the brake hose.
2. 2

   Remove brake rotor
   Remove any retaining screws or clips securing the brake rotor to the hub. Slide the rotor off the hub studs. If the rotor is seized, use penetrating oil and tap gently with a rubber mallet from behind.
3. 3

   Remove axle hub nut
   Fully remove the previously loosened axle hub nut from the drive axle. This nut is typically very tight and may require a breaker bar. Keep the nut for reference if replacing with new hardware.
4. 4

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor connector near the knuckle. Disconnect the electrical connector and carefully unclip or unbolt the sensor from the knuckle. Route the wiring clear of the work area.
5. 5

   Separate tie rod end from knuckle
   Remove the tie rod end castle nut and cotter pin from the rear knuckle. Use a ball joint separator or pickle fork to separate the tie rod end taper from the knuckle. Strike the separator firmly to break the taper fit. Mark tie rod position for approximate alignment during reassembly.
   ⚠Tie rod may release suddenly when taper breaks. Control the separator tool carefully.
6. 6

   Separate lower control arm ball joint
   Remove the lower control arm ball joint castle nut and cotter pin. Use a ball joint separator to break the taper fit between the lower ball joint and knuckle. Apply force gradually and control the knuckle as it separates to prevent damage to the CV axle boot.
7. 7

   Separate upper control arm ball joint
   Remove the upper control arm ball joint castle nut and cotter pin. Use a ball joint separator to separate the upper ball joint from the knuckle. Support the knuckle assembly as it will be free once this connection is broken.
8. 8

   Remove knuckle from drive axle
   With all connections separated, carefully pull the knuckle assembly away from the drive axle splines. If the hub is seized on the axle, use a hub puller to press the axle out of the bearing. Support the axle shaft and protect the CV joint boot from damage. Use a clean rag or plastic bag to cover the exposed axle end.
   ⚠Do not allow the drive axle to hang unsupported as this may damage the inner CV joint or differential seal.
9. 9

   Inspect and prepare new knuckle
   Inspect all ball joint tapers and mounting surfaces on the new knuckle for damage or debris. Clean all mating surfaces with a wire brush. Apply a thin coat of anti-seize to ball joint tapers (not the taper face itself, but the outer threads). If the wheel bearing hub is separate, install it into the knuckle per manufacturer specifications before installation.
10. 10

    Install knuckle onto drive axle
    Align the new knuckle with the drive axle splines and carefully slide it onto the axle shaft. Ensure the axle fully engages with the wheel bearing hub. Thread the new axle hub nut onto the axle shaft by hand to hold the assembly in position, but do not tighten yet.
11. 11

    Connect upper and lower control arms
    Align the knuckle with the upper and lower control arm ball joints. Insert the ball joint tapers into the knuckle and install new castle nuts. Tighten nuts to specification (refer to factory service manual for torque values). Install new cotter pins through the castle nuts and ball joint studs, bending the pins to secure.
12. 12

    Connect tie rod end
    Align the tie rod end with the knuckle steering arm and insert the taper. Install a new castle nut and tighten to specification. Install a new cotter pin and bend to secure. Verify tie rod position matches the reference marks from disassembly for approximate alignment.
13. 13

    Reinstall ABS sensor and brake components
    Reinstall the ABS wheel speed sensor into the knuckle and connect the electrical connector. Ensure the sensor is properly seated and secured. Install the brake rotor onto the hub, then position the brake caliper over the rotor and install new or cleaned caliper mounting bolts to specification.
14. 14

    Final torque axle hub nut
    With the vehicle still supported and brake rotor installed, torque the axle hub nut to manufacturer specification (refer to factory service manual). This typically requires very high torque (200+ ft-lbs). If specified, stake or install a new cotter pin per manufacturer procedure.
15. 15

    Reinstall wheel and perform final checks
    Reinstall the wheel and tire assembly, torquing lug nuts in a star pattern to specification. Lower the vehicle to the ground. Reconnect the 12V battery. Reactivate the high-voltage system per manufacturer procedures. Verify all fasteners are tight and no components are loose or binding.

Reassembly

1. All suspension fasteners must be torqued to manufacturer specifications; refer to factory service manual for exact values as these are critical for safety
2. Always use new castle nuts and cotter pins for all ball joint and tie rod connections
3. Verify ABS sensor connector is fully seated and secured to prevent fault codes
4. Check for any interference between the drive axle boot and surrounding components

Verification

• Perform a four-wheel alignment at a qualified facility immediately after repair
• Test drive the vehicle at low speed in a safe area and verify no unusual noises, vibrations, or handling issues
• Verify ABS warning light does not illuminate and wheel speed sensor is functioning
• Recheck all fastener torques after 50-100 miles of driving
• Inspect for any fluid leaks around the differential or axle seals
• Verify electric power steering functions normally and steering feel is consistent

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