This procedure covers the replacement of the leaf spring U-bolt kit on the 2022 Rivian EDV 500, including removal of old U-bolts and installation of new hardware to secure the rear axle to the leaf springs.

Warnings

Tools required

Parts

• Leaf spring U-bolt kit (includes U-bolts, nuts, and washers) × 1 — Use OEM specification
• U-bolt backing plate (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on a level, solid surface and engage parking brake
2. Place wheel chocks in front of the front wheels
3. Disconnect the 12V battery negative terminal
4. Verify high-voltage system is safely disconnected per Rivian service procedures
5. Loosen rear wheel lug nuts while vehicle is on the ground
6. Raise rear of vehicle using floor jack at designated lift points
7. Support vehicle securely on jack stands rated for the vehicle weight
8. Remove rear wheels completely
9. Spray penetrating oil on existing U-bolt threads and allow to soak for 10-15 minutes

Procedure

1. 1

   Support the rear axle assembly
   Position a transmission jack or adjustable axle support under the center of the rear differential housing. Raise the jack until it just contacts the differential but does not lift the axle. This will support the axle when the U-bolts are removed and prevent it from dropping.
2. 2

   Remove U-bolt nuts
   Using a socket and breaker bar, remove the nuts from all U-bolts on the side being serviced. Remove nuts in a cross-pattern to prevent binding. If nuts are seized, apply additional penetrating oil and allow to soak, or carefully apply heat if conditions permit.
3. 3

   Remove old U-bolts
   Once nuts are removed, extract the U-bolts from the leaf spring assembly. The U-bolts pass through the spring mounting plate and secure the axle to the leaf spring. Tap gently with a rubber mallet if they are stuck in place.
4. 4

   Remove backing plate
   Lower the transmission jack slightly to create clearance between the axle and the leaf spring. Remove the U-bolt backing plate from the top of the axle housing. Inspect the plate for cracks, deformation, or wear. Replace if damaged.
5. 5

   Clean mounting surfaces
   Use a wire brush to clean the axle housing mounting surface, the backing plate, and the leaf spring mounting plate. Remove all rust, debris, and old thread lock compound. Ensure surfaces are clean and flat for proper clamping.
6. 6

   Position backing plate
   Place the backing plate (new or cleaned original) on top of the axle housing in its proper position. Align the U-bolt holes with the corresponding holes in the leaf spring mounting plate below.
7. 7

   Raise axle into position
   Using the transmission jack, carefully raise the axle assembly until the backing plate contacts the underside of the leaf spring firmly. Ensure the axle is centered and properly aligned with the spring before proceeding.
8. 8

   Install new U-bolts
   Insert the new U-bolts from the bottom, passing them through the leaf spring mounting plate, around the axle, and through the backing plate on top. Apply a light coat of anti-seize compound to the threads. Ensure U-bolts are fully seated and threads protrude evenly through the backing plate.
9. 9

   Install washers and nuts
   Place the washers over the U-bolt threads, followed by the nuts. Thread all nuts by hand until they are snug but not tight. This ensures proper alignment before final torquing.
10. 10

    Torque U-bolt nuts to specification
    Using a calibrated torque wrench, tighten the U-bolt nuts in a cross-pattern sequence to the manufacturer's specified torque. Since no specific torque value is listed in the database, consult the Rivian service manual or contact Rivian technical support for the correct specification. Typical commercial vehicle U-bolt torque ranges from 90-120 ft-lbs, but this MUST be verified for this specific vehicle.
11. 11

    Verify axle alignment
    With U-bolts torqued, verify the axle is properly centered on the leaf spring and the backing plate is flush against the spring. Check that all U-bolt threads extend equally through the nuts and no binding or misalignment is present.
12. 12

    Repeat for opposite side if applicable
    If servicing both sides, repeat steps 1-11 for the opposite side of the vehicle. Maintain axle support throughout the process.

Reassembly

1. Remove the transmission jack or axle support from under the differential
2. Reinstall rear wheels and hand-tighten lug nuts
3. Carefully lower the vehicle from jack stands using the floor jack
4. Once vehicle is on the ground, torque wheel lug nuts to specification in a star pattern
5. Reconnect the 12V battery negative terminal
6. Remove wheel chocks

Verification

• Perform a visual inspection of all U-bolt installations to ensure nuts are properly seated and torqued
• Check that there is no gap between the backing plate and leaf spring
• Rock the vehicle side-to-side to verify no unusual movement or noise from the rear suspension
• Test drive the vehicle at low speed in a safe area and listen for any unusual noises or vibrations
• After 50-100 miles of driving, re-torque U-bolt nuts to specification as initial settling may occur
• Verify high-voltage system is functioning properly if it was disconnected during service

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