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

Warnings

Tools required

Parts

• Rear upper control arm × 1 — Use OEM specification
• Upper control arm mounting bolts × 2 — Use OEM specification
• Upper ball joint nut × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 2 minutes for system shutdown
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Raise rear of vehicle using floor jack at designated rear lift point
5. Support vehicle on jack stands at manufacturer-specified frame points
6. Remove rear wheel on side being serviced
7. Spray all control arm mounting bolts and ball joint nut with penetrating oil and allow to soak for 10 minutes

Procedure

1. 1

   Support rear suspension
   Position floor jack under rear lower control arm or knuckle assembly to support suspension weight. Raise jack until suspension is at normal ride height position. This prevents suspension from dropping when upper control arm is disconnected.
2. 2

   Mark alignment position
   Using a paint pen or marker, mark the position of the upper control arm relative to the mounting bracket on the frame. This provides a reference point for initial reinstallation alignment, though professional alignment will still be required.
3. 3

   Remove upper ball joint nut
   Locate the upper ball joint at the knuckle assembly. Remove the cotter pin if equipped. Using a 19mm or 21mm socket (verify size for your specific model), remove the upper ball joint castle nut. Keep nut for comparison with replacement part.
4. 4

   Separate ball joint from knuckle
   Insert ball joint separator tool between the knuckle and upper control arm. Apply pressure to pop ball joint taper free from knuckle. Alternatively, use a pickle fork if separator is not available, but note this may damage the ball joint boot. Tap separator with hammer if needed to break taper seal.
5. 5

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the frame bracket. Using appropriate socket (typically 21mm), remove the bolt while supporting the control arm. Note the orientation of any washers or spacers for reinstallation.
6. 6

   Remove front control arm mounting bolt
   Locate the front mounting bolt at the frame bracket. Remove this bolt while continuing to support the control arm weight. The control arm should now be free from the vehicle. Carefully lower and remove the control arm.
7. 7

   Inspect mounting points
   Inspect frame mounting brackets for cracks, damage, or elongated bolt holes. Check knuckle ball joint taper seat for damage or deformation. Clean mounting bolt holes with wire brush and inspect rubber bushings in mounting brackets if equipped. Replace any damaged components before proceeding.
8. 8

   Install new control arm
   Position new upper control arm into place, aligning with frame mounting brackets. Insert front mounting bolt first, threading it hand-tight but do not fully tighten. Insert rear mounting bolt and thread hand-tight. Ensure control arm is positioned at previously marked alignment reference.
9. 9

   Connect ball joint to knuckle
   Raise or lower jack supporting suspension as needed to align upper control arm ball joint with knuckle taper hole. Insert ball joint stud into knuckle and install new castle nut. Thread nut hand-tight, ensuring ball joint seats properly into taper.
10. 10

    Torque ball joint nut
    With suspension at ride height, torque the upper ball joint nut to manufacturer specification. Since specific torque value is not available in database, reference Rivian service information or use typical specification of 75-90 lb-ft for this class of vehicle. Install new cotter pin if equipped and bend tabs to secure.
11. 11

    Torque control arm mounting bolts
    With suspension supported at normal ride height position, torque front and rear control arm mounting bolts to manufacturer specification. Since specific torque values are not available in database, reference Rivian service information. Typical specifications for this vehicle class are 125-150 lb-ft. Bolts must be torqued at ride height to prevent bushing binding.
12. 12

    Remove support and reinstall wheel
    Carefully lower and remove floor jack from under suspension. Inspect all connections visually. Reinstall wheel and hand-tighten lug nuts in star pattern. Lower vehicle to ground and torque lug nuts to specification (typically 140-150 lb-ft for Rivian EDV).

Reassembly

1. Reconnect 12V battery negative terminal
2. Start vehicle and verify no warning lights related to suspension or stability control systems
3. Torque wheel lug nuts to final specification after vehicle is on ground

Verification

• Perform visual inspection of all mounting bolts and ball joint connection
• Check that control arm has full range of motion without binding
• Test drive at low speed in safe area and listen for unusual noises from rear suspension
• Schedule wheel alignment immediately - verify camber, caster, and toe are within specification
• After alignment, verify vehicle tracks straight and steering wheel is centered
• Re-torque all fasteners after 50-100 miles of driving

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