Torsion Bar

This procedure covers the removal and replacement of the torsion bar assembly on a 2022 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Torsion bar × 1 — Use OEM specification
• Torsion bar adjuster bolt × 1 — Use OEM specification
• Torsion bar key × 1 — Use OEM specification
• Torsion bar mounting hardware × 1 — Use OEM specification

Preparation

1. Park vehicle on a level surface and apply parking brake
2. Place wheel chocks behind wheels that will remain on the ground
3. Disconnect the 12V auxiliary battery negative terminal
4. Verify the high-voltage system is disabled per manufacturer safety procedures
5. Measure and document current ride height at all four corners for reference
6. Mark the torsion bar adjuster bolt position with paint marker or chalk
7. Count and document the number of threads showing on the adjuster bolt
8. Raise and support the vehicle on jack stands at manufacturer-specified lift points
9. Remove the wheel on the side where torsion bar is being replaced

Procedure

1. 1

   Access the torsion bar adjuster
   Locate the torsion bar adjuster assembly at the rear of the lower control arm. Clean the area around the adjuster bolt with a wire brush. Apply penetrating oil to the adjuster bolt threads and allow to soak for several minutes.
2. 2

   Install torsion bar unloading tool
   Install the torsion bar unloading tool onto the adjuster arm according to the tool manufacturer's instructions. Ensure the tool is properly seated and aligned before applying any force. The tool must securely engage both the adjuster key and the crossmember.
   ⚠️The torsion bar unloading tool must be properly installed before loosening the adjuster bolt. Failure to do so can result in the adjuster key violently ejecting.
3. 3

   Unload torsion bar tension
   Using the torsion bar unloading tool, apply tension to the adjuster arm to slightly load the tool. This removes pressure from the adjuster bolt. Turn the tool's forcing screw clockwise to compress the adjuster assembly approximately 1/4 inch. This relieves tension on the adjuster bolt lock nut.
4. 4

   Remove adjuster bolt
   Remove the adjuster bolt lock nut completely. Back out the adjuster bolt while counting the turns for reference during reassembly. Continue slowly unloading the torsion bar using the unloading tool until all tension is released from the adjuster arm. Remove the adjuster bolt completely once tension is fully released.
5. 5

   Remove torsion bar key
   With tension fully released, remove the torsion bar key from the adjuster arm. The key is indexed and can only be installed one way. Note the orientation and mark if necessary. Inspect the key for wear or damage.
6. 6

   Remove torsion bar from rear mount
   Locate the torsion bar rear mount at the vehicle frame. Remove the retaining clip or bolt securing the torsion bar to the rear crossmember mount. The torsion bar should now be free at the rear but still engaged in the lower control arm at the front.
7. 7

   Remove torsion bar from control arm
   At the front of the torsion bar, carefully slide the torsion bar rearward out of the lower control arm socket. The bar may require gentle prying or tapping with a soft mallet. Note the spline orientation as torsion bars are side-specific and marked 'L' or 'R'.
   ⚠Torsion bars are side-specific. Installing the wrong side will result in improper suspension geometry and handling problems. Verify left and right markings.
8. 8

   Inspect mounting points
   Inspect the lower control arm socket and rear crossmember mount for wear, damage, or corrosion. Clean both mounting surfaces thoroughly with a wire brush. Check that the hex or spline sockets are not rounded or damaged. Replace any worn components before installing the new torsion bar.
9. 9

   Install new torsion bar
   Verify the new torsion bar is marked for the correct side (L or R). Apply a thin coat of anti-seize compound to the splines at both ends of the torsion bar. Insert the front end of the torsion bar into the lower control arm socket, aligning the splines. Ensure the bar is fully seated.
10. 10

    Secure rear mount
    Slide the rear of the torsion bar into the crossmember mount. Align the mounting hole and install the retaining clip or bolt. Ensure the torsion bar is properly positioned in both the front and rear mounts before proceeding.
11. 11

    Install torsion bar key
    Position the torsion bar key onto the torsion bar adjuster arm with the correct orientation. The key is indexed and will only fit one way. Ensure the key is fully seated on the bar splines and properly positioned in the adjuster arm slot.
12. 12

    Load torsion bar with unloading tool
    Reinstall the torsion bar unloading tool onto the adjuster arm and key. Turn the forcing screw to apply tension and compress the adjuster assembly, allowing clearance for the adjuster bolt installation. Apply enough tension to align the adjuster bolt hole.
13. 13

    Install and adjust adjuster bolt
    Install the adjuster bolt through the key and into the adjuster arm. Thread the bolt in to approximately the same number of turns documented during removal, or until the paint marks align. Install the lock nut but do not fully tighten yet. Slowly release tension on the unloading tool to transfer load to the adjuster bolt. Remove the unloading tool once load is transferred.
14. 14

    Perform initial ride height adjustment
    Lower the vehicle to the ground. Bounce the suspension several times to settle the components. Measure the ride height and compare to the pre-service measurements and manufacturer specifications. Adjust the torsion bar adjuster bolt as needed to achieve proper ride height. Turn clockwise to increase height, counterclockwise to decrease.
15. 15

    Final tightening and verification
    Once proper ride height is achieved, tighten the adjuster bolt lock nut securely. Reinstall the wheel and lower the vehicle completely. Torque the wheel lug nuts to specification in a star pattern. Bounce each corner of the vehicle again and recheck ride height measurements to verify they are within specification.

Reassembly

1. Torque all fasteners to manufacturer specifications once available
2. Ensure the torsion bar adjuster lock nut is properly tightened
3. Verify ride height is within manufacturer specifications at all four corners
4. Reconnect the 12V auxiliary battery negative terminal
5. Verify all tools and parts have been removed from under the vehicle

Verification

• Measure and verify ride height matches pre-service measurements or manufacturer specifications
• Perform a visual inspection to ensure the torsion bar is properly seated at both mounting points
• Test drive the vehicle in a safe area and verify normal suspension operation
• Listen for any unusual noises during suspension articulation
• Schedule a four-wheel alignment as suspension geometry will be affected by this repair
• Recheck ride height after 50-100 miles of driving and readjust if necessary

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