This procedure covers the removal and installation of the front or rear subframe on a 2022 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Subframe mounting bolts × 1 — Use OEM specification
• Subframe bushing set (if damaged) × 1 — Use OEM specification
• Control arm mounting hardware (as needed) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil (front differential) — 1.5 qt
• 75W-90 GL-5 Gear Oil (rear differential) — 2 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind wheels that will remain on ground
3. Disconnect 12V battery negative terminal and isolate high voltage system per Rivian service procedures
4. Wait minimum 5 minutes for capacitor discharge
5. Raise vehicle on lift to working height with all wheels off ground
6. Remove all four wheels and set aside
7. Photograph subframe area, suspension components, and all electrical connections for reference
8. Spray all subframe bolts and mounting hardware with penetrating oil
9. If servicing front subframe, place drain pan underneath and drain front differential completely
10. If servicing rear subframe, place drain pan underneath and drain rear differential completely

Procedure

1. 1

   Disconnect steering and brake components
   Disconnect the steering linkage from the steering rack (front subframe) or disconnect parking brake cables and ABS sensor wiring (rear subframe). Remove brake calipers and support them with wire to avoid stressing brake lines. Do not allow calipers to hang by the brake hoses.
2. 2

   Remove drive unit mounting bolts
   Remove all bolts securing the electric drive unit to the subframe. The front or rear motor assembly may need to be supported with a separate jack. Note that drive units are extremely heavy (approximately 200+ lbs). Support the drive unit before removing final mounting bolts.
3. 3

   Disconnect suspension components
   Remove lower control arm mounting bolts from the subframe. Disconnect stabilizer bar end links from control arms or subframe mounting points. Remove shock absorber lower mounting bolts. Allow suspension components to hang safely or support them as needed.
4. 4

   Disconnect electrical and cooling connections
   Carefully disconnect all electrical connectors routed to or through the subframe area. Disconnect any motor cooling lines if attached to the subframe. Cap all open coolant fittings immediately to prevent contamination. Label all connections for reassembly.
5. 5

   Remove differential if equipped on subframe
   If the differential housing is mounted to the subframe being removed, disconnect the driveshafts and remove all differential mounting bolts. Support the differential with a separate jack and carefully lower it away from the subframe, or leave it supported for removal with the subframe as a complete assembly.
6. 6

   Position transmission jack under subframe
   Place a transmission jack or subframe support fixture under the center of the subframe. Raise slightly to take weight off the mounting bolts but do not lift the subframe. Ensure the subframe is securely positioned on the jack and cannot shift during lowering.
7. 7

   Remove subframe mounting bolts
   Locate all subframe-to-body mounting bolts (typically 4-6 bolts). Using a breaker bar and appropriate socket, remove all mounting bolts while supporting the subframe with the jack. Note the position and length of each bolt as they may be different sizes. Check for any additional brackets or ground straps attached to subframe mounting points.
8. 8

   Lower and remove subframe
   Carefully lower the transmission jack while guiding the subframe away from the vehicle body. Watch for any wiring, hoses, or components that may still be attached. Lower slowly and check clearance around battery pack enclosure. Once clear of the vehicle, roll the jack out from under the vehicle.
9. 9

   Inspect subframe and mounting points
   Inspect the subframe for cracks, corrosion, or damage. Check all bushings for tears, deterioration, or excessive wear. Inspect vehicle body mounting points for damage, elongated holes, or corrosion. Clean all mounting surfaces with a wire brush. Replace any damaged bushings or hardware.
10. 10

    Position new or serviced subframe
    Place the subframe on the transmission jack and raise into approximate position under the vehicle. Align the subframe mounting holes with body mounting points. Use alignment pins or a subframe alignment tool if available to ensure proper positioning. Raise the subframe until it contacts the body mounting surfaces.
11. 11

    Install subframe mounting bolts
    Install all subframe mounting bolts hand-tight first to ensure proper alignment. Apply medium-strength thread locker to bolt threads per manufacturer specification. Verify subframe is properly seated against all mounting surfaces. Since no torque specifications are available in the database, refer to the Rivian service manual for proper torque values and tightening sequence.
12. 12

    Reconnect suspension and steering components
    Reinstall lower control arms to subframe mounting points. Reconnect stabilizer bar end links. Install shock absorber lower mounting bolts. Reconnect steering linkage (front) or parking brake cables (rear). Ensure all suspension components move freely through their range of motion.
13. 13

    Reinstall drive unit and differential
    Position the electric drive unit back onto the subframe and install all mounting bolts. If removed separately, reinstall the differential assembly to the subframe and reconnect driveshafts. Ensure proper alignment of all mating surfaces before tightening fasteners.
14. 14

    Reconnect electrical and cooling systems
    Reconnect all electrical connectors using your reference photos. Reconnect motor cooling lines and ensure fittings are properly torqued to prevent leaks. Verify all wiring harnesses are properly routed and secured away from moving components and heat sources.
15. 15

    Reinstall brake components and refill fluids
    Reinstall brake calipers to their mounting brackets. Refill the appropriate differential with 75W-90 GL-5 gear oil to specification (1.5 qt front, 2.0 qt rear). Check and top off EV motor coolant as needed. Bleed brakes if any brake lines were disconnected.

Reassembly

1. Install all four wheels and torque lug nuts to specification
2. Lower vehicle to ground
3. Reconnect 12V battery and restore high voltage system per manufacturer procedures
4. Perform system initialization and clear any diagnostic codes
5. Test all electrical functions including sensors and lighting affected by the repair

Verification

• Visually inspect all connections and fasteners for proper installation
• Check for fluid leaks around differential and cooling system connections
• Perform a walk-around inspection to ensure no tools or parts were left in vehicle
• Test drive vehicle at low speed in a safe area to verify no unusual noises or handling issues
• Schedule four-wheel alignment immediately - suspension geometry has been altered
• Verify all warning lights are off and no diagnostic codes are present
• Re-torque all subframe mounting bolts after 50-100 miles of driving

More procedures for this vehicle