This procedure covers the removal and replacement of leaf spring shackles on the 2022 Rivian EDV 500 commercial van, including disassembly of the rear suspension mounting hardware.

Warnings

Tools required

Parts

• Leaf spring shackle assembly × 1 — Use OEM specification
• Shackle bushings × 2 — Use OEM specification
• Shackle bolt kit × 1 — Use OEM specification
• Lock nuts × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks at front wheels
3. Disconnect 12V auxiliary battery negative terminal
4. Raise vehicle on lift or jack stands to working height, ensuring stability
5. Remove rear wheel on the side requiring shackle replacement
6. Spray all shackle bolt threads with penetrating oil and allow 15-20 minutes for penetration
7. Visually inspect the leaf spring, shackle, and frame mounting points for additional damage or wear

Procedure

1. 1

   Support the rear axle
   Position a floor jack under the rear axle housing near the leaf spring being serviced. Raise the jack until it just contacts the axle and takes minimal load. This prevents the axle from dropping when the shackle is disconnected and maintains proper working position.
2. 2

   Remove lower shackle bolt
   Locate the lower shackle bolt that connects the shackle to the rear end of the leaf spring. Hold the nut with a wrench while loosening the bolt head from the opposite side. Remove the bolt completely and set aside. Note the orientation of any washers or spacers for reinstallation.
3. 3

   Remove upper shackle bolt
   Locate the upper shackle bolt that connects the shackle to the frame bracket. Hold the nut with a wrench while loosening the bolt head. Remove the bolt completely. The shackle assembly should now be free to remove.
4. 4

   Remove shackle assembly
   Pull the shackle assembly away from the leaf spring and frame bracket. If the shackle is binding on worn bushings, use a pry bar carefully to separate it. Inspect the removed shackle for cracks, deformation, or excessive wear.
5. 5

   Inspect and clean mounting points
   Thoroughly inspect the frame bracket and leaf spring eye for damage, cracks, or elongated holes. Use a wire brush to clean both mounting surfaces and bolt holes, removing all rust, dirt, and debris. Check that bolt holes are not wallowed out or damaged.
6. 6

   Prepare new shackle assembly
   If new bushings are separate from the shackle, press or drive them into the shackle eyes ensuring they are fully seated. Apply a light coating of assembly lubricant to bushing surfaces. Verify the new shackle matches the original design and dimensions.
7. 7

   Position new shackle assembly
   Align the new shackle between the frame bracket and leaf spring eye. Ensure proper orientation with any offset or angle matching the original installation. The shackle should move freely without binding.
8. 8

   Install upper shackle bolt
   Insert the upper shackle bolt through the frame bracket and shackle eye. Install washers in their original positions. Thread the lock nut onto the bolt but do not fully tighten yet. Ensure the bolt passes through all components smoothly.
9. 9

   Install lower shackle bolt
   Insert the lower shackle bolt through the shackle and leaf spring eye. Install washers in their original positions. Thread the lock nut onto the bolt but do not fully tighten. Verify all components are properly aligned.
10. 10

    Load suspension to ride height
    Using the floor jack under the axle, slowly raise the axle until the suspension reaches normal ride height position. This ensures bushings are torqued in their operating position, preventing premature wear and binding.
11. 11

    Torque shackle bolts
    With suspension at ride height, torque both the upper and lower shackle bolts to manufacturer specification. Without factory specifications available, follow Rivian service bulletin guidance or use conservative torque values appropriate for commercial vehicle suspension fasteners (typically 120-150 ft-lb for this application). Torque the nut while holding the bolt head stationary.
12. 12

    Lower axle jack and verify movement
    Carefully lower and remove the floor jack from under the axle. Manually push up and down on the rear bumper to cycle the suspension through its travel. Verify the shackle moves freely without binding or unusual noise.

Reassembly

1. Reinstall the rear wheel and torque lug nuts to Rivian specification in a star pattern
2. Lower vehicle to ground
3. Reconnect 12V auxiliary battery negative terminal
4. Remove wheel chocks

Verification

• Perform a visual inspection of the installed shackle to ensure all bolts are present and properly seated
• Rock the vehicle side-to-side and verify no unusual noises or movement from the shackle area
• Test drive the vehicle at low speed over varied terrain and listen for any suspension noises
• After 50-100 miles of driving, re-inspect shackle bolts for proper torque retention
• Verify suspension ride height is correct and equal side-to-side

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