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

Warnings

Tools required

Parts

• Lower control arm (left or right as needed) × 1 — Use OEM specification
• Control arm to frame mounting bolts × 2 — Use OEM specification
• Ball joint castle nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on a level, solid surface and engage parking brake
2. Chock the rear wheels securely
3. Disconnect the 12V battery negative terminal to prevent electrical issues during suspension work
4. If available, follow Rivian procedures to safely disable the high-voltage system
5. Loosen the wheel lug nuts while vehicle is on the ground (do not remove)
6. Raise the vehicle using a floor jack at the manufacturer-specified jacking point
7. Support the vehicle securely on jack stands at designated support points
8. Remove the wheel and tire assembly completely
9. Spray all fasteners to be removed with penetrating oil and allow to soak for 10-15 minutes
10. Photograph or mark the position of any adjustable components for reference during reassembly

Procedure

1. 1

   Support the knuckle assembly
   Position a floor jack with a block of wood under the steering knuckle to support the weight of the suspension and prevent the assembly from dropping when the control arm is disconnected. Raise the jack just enough to take up slack but not lift the vehicle.
2. 2

   Remove the ball joint cotter pin and castle nut
   Locate the lower ball joint where it connects to the steering knuckle. Straighten and remove the cotter pin from the castle nut. Using the appropriate socket, loosen and remove the castle nut from the ball joint stud. Keep the nut accessible as you may need to thread it back on partially during separation.
3. 3

   Separate the ball joint from the knuckle
   Use a ball joint separator tool or pickle fork to break the taper connection between the ball joint and the steering knuckle. Insert the tool between the control arm and knuckle, and strike or apply pressure according to the tool type until the joint releases. If the joint is stubborn, thread the castle nut back on a few turns to protect the stud threads before striking. Once separated, lower the jack slightly to allow clearance for control arm removal.
4. 4

   Disconnect sway bar link if equipped
   If the lower control arm has a sway bar end link attached, locate the connection point on the control arm. Hold the ball stud with a hex key or wrench to prevent spinning, then remove the retaining nut. Separate the end link from the control arm and secure it out of the way with wire or a bungee cord to prevent strain on the bushings.
5. 5

   Identify and mark control arm mounting bolts
   Locate the front and rear mounting bolts that secure the control arm to the subframe or chassis. These typically use large diameter bolts with washers. Note the orientation of any eccentric washers or cam bolts used for alignment adjustment. Take photos or mark positions with paint pen for reference during installation.
6. 6

   Remove the rear control arm mounting bolt
   Using a breaker bar and appropriate socket, loosen and remove the rear mounting bolt that secures the control arm to the frame. Support the control arm by hand as you remove the bolt completely. The bushing may remain attached to the control arm or stay on the mounting point.
7. 7

   Remove the front control arm mounting bolt
   Remove the front mounting bolt in the same manner as the rear. Once this bolt is removed, the control arm will be free. Carefully maneuver the control arm out from between the subframe and steering knuckle. You may need to angle or rotate the arm to clear obstacles.
8. 8

   Inspect mounting points and clean surfaces
   With the control arm removed, inspect the subframe mounting points for damage, excessive corrosion, or deformed bolt holes. Use a wire brush to clean the mounting surfaces and bolt holes. Inspect the steering knuckle ball joint taper seat for damage or deformation. Clean any dirt or corrosion from all mating surfaces.
9. 9

   Position and install the new control arm
   Position the new lower control arm into place, aligning the bushings with the front and rear mounting points on the subframe. The ball joint should be oriented toward the steering knuckle. Insert the front and rear mounting bolts through the bushings and into the frame mounts. Thread the bolts by hand initially but do not tighten yet. The suspension should be at normal ride height when final torque is applied.
10. 10

    Connect the ball joint to the knuckle
    Raise the floor jack under the knuckle to align the ball joint stud with the hole in the steering knuckle. You may need to use a pry bar to align the holes. Insert the ball joint stud into the knuckle taper. Thread the new castle nut onto the ball joint stud and tighten to draw the taper fully seated. Do not apply final torque yet.
11. 11

    Reconnect sway bar link if equipped
    If previously disconnected, reconnect the sway bar end link to the control arm. Install the retaining nut and tighten while holding the ball stud with a hex key to prevent rotation. Tighten according to manufacturer specifications if available.
12. 12

    Load suspension to ride height and torque all fasteners
    This is a critical step. Lower the vehicle onto the jack stands or use the floor jack to compress the suspension to simulate normal ride height (wheels on ground position). With the suspension loaded, torque the front and rear control arm mounting bolts according to Rivian specifications. Then torque the ball joint castle nut to specification. If the cotter pin holes do not align, tighten further (never loosen) until aligned. Install a new cotter pin and bend the ends to secure.
    ⚠Control arm bushings must be torqued at ride height to prevent premature bushing failure. Do not torque with suspension hanging.
13. 13

    Reinstall wheel and lower vehicle
    Mount the wheel and tire assembly onto the hub. Install the lug nuts and tighten in a star pattern by hand. Lower the vehicle carefully to the ground and remove jack stands. With the vehicle on the ground, torque the lug nuts to Rivian specification in a star pattern.

Reassembly

1. Ensure all suspension fasteners are tightened to specification with the suspension at ride height
2. Verify the ball joint cotter pin is properly installed and bent to prevent backing out
3. Double-check that no tools or parts were left in the wheel well area
4. Reconnect the 12V battery negative terminal

Verification

• Before driving, bounce each corner of the vehicle to verify the suspension moves freely without binding or unusual noises
• Perform a careful test drive at low speed in a safe area, listening for any clunks or unusual sounds from the suspension
• Check for proper steering feel and response
• Verify no warning lights are illuminated on the instrument cluster
• Schedule a professional wheel alignment as soon as possible, as the vehicle will not track properly without alignment after control arm replacement
• After the first 50-100 miles, re-check all fasteners for proper torque

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