This procedure covers the removal and replacement of the front lower control arm on a 2022 Rivian EDV 500 commercial delivery van with dual motor AWD electric drivetrain.

Warnings

Tools required

Parts

• Front lower control arm assembly × 1 — Use OEM Rivian specification
• Lower ball joint castle nut (if not reusable) × 1 — Use OEM specification
• Control arm mounting bolts (if not reusable) × 2 — Use OEM specification
• Cotter pin for ball joint × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Open frunk and disconnect 12V battery negative terminal
4. Wait 5 minutes for vehicle systems to fully power down
5. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
6. Raise front of vehicle with floor jack at designated lift points
7. Support vehicle securely on jack stands at rated jacking points on frame
8. Remove front wheel on side being serviced
9. Spray all suspension fasteners with penetrating lubricant and allow to soak

Procedure

1. 1

   Access and inspect control arm area
   With the wheel removed, visually inspect the lower control arm, ball joint, and mounting points. Note the orientation of washers, spacers, and any alignment shims for reinstallation. Take photos if helpful for reference during reassembly.
2. 2

   Support lower suspension
   Position a floor jack under the lower control arm near the ball joint to support the suspension assembly. Raise jack just enough to take light pressure off the control arm but not to lift the vehicle. This prevents the suspension from dropping when the control arm is disconnected.
3. 3

   Disconnect stabilizer bar link
   Locate the stabilizer bar end link connection to the lower control arm. Using appropriate sockets, remove the nut securing the stabilizer link to the control arm. Hold the link stud with a wrench to prevent spinning if necessary. Support the link with wire to prevent it from hanging and damaging the boot.
4. 4

   Remove ball joint cotter pin and nut
   Remove the cotter pin from the lower ball joint castle nut using pliers or cotter pin removal tool. Discard the cotter pin. Using a socket and breaker bar, loosen and remove the castle nut from the ball joint stud. Do not fully remove the nut until the ball joint taper is broken.
5. 5

   Separate ball joint from knuckle
   With the castle nut backed off several turns (but still threaded on), use a ball joint separator tool or pickle fork to break the taper between the ball joint stud and steering knuckle. Strike the separator firmly with a hammer if using a pickle fork. Once the taper is broken, remove the castle nut completely and lower the control arm away from the knuckle using the floor jack.
   ⚠The ball joint may release suddenly when the taper breaks. Keep hands and face clear of the separation point.
6. 6

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the subframe or front crossmember. This bolt typically runs horizontally through a bushing. Using a socket and breaker bar, remove the bolt completely. Note the position and orientation of any washers or bushings for reinstallation.
7. 7

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the subframe. This may be accessed from the rear of the control arm. Remove the bolt completely using appropriate sockets. Support the control arm as you remove the final mounting point to prevent it from falling.
8. 8

   Remove control arm from vehicle
   With all fasteners removed, carefully maneuver the lower control arm out of the suspension area. It may need to be rotated or angled to clear the steering knuckle, brake components, and subframe. Lower the floor jack as needed to create clearance.
9. 9

   Prepare mounting points and new control arm
   Clean all mounting surfaces on the subframe using a wire brush. Remove any corrosion, debris, or old thread locking compound from bolt holes. Inspect the mounting points for damage or cracks. Clean the new control arm mounting surfaces and verify that all bushings are properly seated and oriented correctly.
10. 10

    Install new control arm
    Position the new lower control arm into the mounting location. Align the bushings with the mounting points on the subframe. Insert the rear mounting bolt first (do not tighten), then the front mounting bolt. Thread both bolts by hand to ensure proper alignment before any tightening occurs.
11. 11

    Connect ball joint to steering knuckle
    Raise the floor jack to lift the control arm and align the ball joint stud with the hole in the steering knuckle. Insert the stud fully into the knuckle taper. Install the castle nut and tighten by hand. Use a torque wrench to tighten the castle nut to specification (refer to official Rivian service manual). Align the castle nut slots with the stud hole and install a new cotter pin, bending the ends to secure.
12. 12

    Reconnect stabilizer bar link
    Position the stabilizer bar end link to the lower control arm mounting point. Install the mounting nut and tighten to specification (refer to official Rivian service manual). Hold the link stud with a wrench if it begins to spin during tightening.
13. 13

    Torque control arm mounting bolts
    With the suspension at ride height (vehicle weight on wheels or jack supporting suspension at normal height), torque the front and rear control arm mounting bolts to specification using a calibrated torque wrench. Refer to official Rivian service documentation for proper torque values. Do not fully tighten these bolts with the suspension hanging, as this will preload the bushings incorrectly and cause premature wear.
    ⚠Control arm mounting bolts must be torqued at ride height to prevent bushing binding and premature failure.
14. 14

    Reinstall wheel and lower vehicle
    Reinstall the front wheel and thread lug nuts by hand. Lower the vehicle from jack stands using the floor jack until the wheel contacts the ground but vehicle weight is not fully transferred. Torque lug nuts in a star pattern to manufacturer specification (typically 140-150 ft-lb for Rivian, but verify). Lower vehicle completely and remove jack stands.

Reassembly

1. Reconnect 12V battery negative terminal in frunk
2. Start vehicle and verify no warning lights related to suspension or stability control
3. Test drive vehicle in a safe area at low speed to verify proper suspension operation and no unusual noises
4. Schedule front end alignment as soon as possible - control arm replacement affects camber and caster angles

Verification

• Verify all mounting bolts are torqued to specification and properly secured
• Confirm ball joint castle nut is secured with new cotter pin properly bent
• Check that stabilizer bar link is properly connected and not binding
• Bounce front end of vehicle and listen for any unusual noises or clunking
• Verify wheel lug nuts are torqued to specification
• Have front end alignment checked and adjusted by qualified technician with proper equipment
• Test drive vehicle and verify straight-line tracking and no pulling to either side
• Re-check all fastener torque after 50-100 miles of driving

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