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

Warnings

Tools required

Parts

• Front upper control arm assembly × 1 — Use OEM specification
• Upper ball joint castle nut × 1 — Use OEM specification
• Control arm mounting bolts/nuts × 2 — Use OEM specification
• Cotter pin (if equipped) × 1 — Use OEM specification

Preparation

1. Park vehicle on a level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal and wait 2 minutes
4. Loosen front wheel lug nuts while vehicle is on the ground
5. Raise front of vehicle with floor jack at designated lift points
6. Support vehicle securely on jack stands rated for vehicle weight
7. Remove front wheel on the side being serviced
8. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Mark alignment reference points
   Before removal, use a paint pen or marking tool to mark the position of the upper control arm mounting bolts relative to the mounting brackets. This will provide a baseline for initial alignment during reinstallation.
2. 2

   Support the lower control arm
   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 upper control arm, preventing the suspension from dropping when the upper ball joint is disconnected.
3. 3

   Remove upper ball joint castle nut
   If equipped with a cotter pin, remove and discard it. Using a 21mm socket, remove the castle nut securing the upper ball joint to the steering knuckle. Keep track of any washers or spacers present.
4. 4

   Separate upper ball joint from knuckle
   Install a ball joint separator tool between the upper control arm and steering knuckle. Tighten the separator tool to apply pressure, then strike the knuckle boss area with a hammer to shock the taper loose. Do not use excessive force that could damage the knuckle or control arm threads.
5. 5

   Remove front control arm mounting bolt
   Locate the front mounting bolt securing the upper control arm to the frame bracket. Using a 19mm socket and wrench to hold the nut, remove the bolt completely. Note the orientation of the bolt for reinstallation.
6. 6

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt securing the upper control arm to the frame bracket. Using a 19mm socket and wrench to hold the nut, remove the bolt completely. Support the control arm as you remove the final fastener.
7. 7

   Remove upper control arm
   Carefully lower and maneuver the upper control arm away from the mounting brackets and knuckle. Inspect the mounting bushings and ball joint boot on the removed arm to identify any wear patterns or damage that led to replacement.
8. 8

   Clean mounting surfaces
   Using a wire brush, clean the mounting bracket surfaces on the frame and the ball joint taper seat in the steering knuckle. Remove any corrosion, dirt, or debris. Inspect threads in the knuckle for damage.
9. 9

   Install new upper control arm
   Position the new upper control arm into the frame mounting brackets, aligning with the reference marks made during disassembly. Insert the ball joint stud into the steering knuckle taper. Hand-start both mounting bolts but do not fully tighten yet.
10. 10

    Install upper ball joint castle nut
    Install the new castle nut onto the upper ball joint stud. Tighten the nut until the ball joint taper is fully seated and the nut reaches proper torque specification. Since no torque specification is provided in the database, follow Rivian service manual specifications. Align castle nut slots with ball joint stud hole and install new cotter pin if equipped.
11. 11

    Torque control arm mounting bolts
    With the suspension at ride height (jack supporting lower control arm), torque both front and rear upper control arm mounting bolts to manufacturer specification. Since no torque specification is provided in the database, follow Rivian service manual specifications. Tighten bolts in the sequence: front bolt first, then rear bolt. Apply medium-strength thread locker if specified by manufacturer.
12. 12

    Remove jack support
    Carefully lower and remove the floor jack from beneath the lower control arm. Verify all fasteners are properly installed and tightened.

Reassembly

1. Reinstall wheel and hand-tighten lug nuts in a star pattern
2. Lower vehicle to the ground and remove jack stands
3. Torque wheel lug nuts to specification in a star pattern
4. Reconnect 12V battery negative terminal
5. Rock vehicle side-to-side to settle suspension before final inspection
6. Verify all tools and parts have been removed from work area

Verification

• Visually inspect that all fasteners are installed and properly torqued
• Verify upper ball joint castle nut is properly secured with cotter pin if equipped
• Check that there is no unusual play or movement in the upper control arm
• Test drive vehicle at low speed in a safe area and listen for any abnormal noises
• Schedule a four-wheel alignment as soon as possible - this is mandatory after suspension component replacement
• After 50-100 miles, re-check all mounting fasteners for proper torque

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