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

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification
• Upper ball joint (if not included with control arm) × 1 — Use OEM specification
• Control arm mounting bolts/hardware × 1 — Use OEM specification
• Lock nuts × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal
4. Power down high voltage system per Rivian service manual procedures
5. Loosen lug nuts on affected wheel while vehicle is on ground
6. Raise vehicle using floor jack at manufacturer-specified lift point
7. Support vehicle on properly rated jack stands at designated support points
8. Remove wheel and tire assembly
9. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes
10. Take reference photos of control arm position and orientation

Procedure

1. 1

   Remove wheel speed sensor bracket
   If the wheel speed sensor wiring or bracket is attached to the upper control arm, carefully disconnect any clips or fasteners securing it. Move the sensor wiring out of the work area and secure it to prevent damage.
2. 2

   Support lower control arm
   Position a floor jack under the lower control arm to support the suspension weight. Raise the jack just enough to take up the load but not lift the vehicle. This prevents the suspension from dropping when the upper control arm is disconnected.
3. 3

   Separate upper ball joint from knuckle
   Remove the castle nut or lock nut securing the upper ball joint stud to the steering knuckle. If equipped with a cotter pin, remove and discard it first. Use a ball joint separator tool or pickle fork to break the taper between the ball joint stud and knuckle. Strike the tool firmly but avoid damaging the threads on the ball joint stud.
4. 4

   Remove front upper control arm mounting bolt
   Locate the front mounting point where the upper control arm attaches to the frame or suspension tower. Remove the bolt and any washers or spacers, noting their positions. Support the control arm to prevent it from dropping. Some models may have eccentric bolts or cam adjustment hardware for alignment purposes.
5. 5

   Remove rear upper control arm mounting bolt
   Locate the rear mounting point where the upper control arm attaches to the frame or suspension tower. Remove the bolt and any washers or spacers, noting their positions and orientation. Keep all alignment shims or adjustment hardware with their respective positions marked for reference.
6. 6

   Remove upper control arm from vehicle
   With both mounting bolts removed and the ball joint separated, carefully maneuver the upper control arm out of the suspension assembly. It may be necessary to angle or rotate the control arm to clear other components. Inspect the mounting points on the frame for wear, damage, or rust.
7. 7

   Inspect and clean mounting points
   Thoroughly inspect all mounting points on the frame, steering knuckle, and suspension components for damage, cracks, or excessive wear. Use a wire brush to clean the mounting bolt holes and threaded areas. Check the steering knuckle ball joint taper for damage. Replace any damaged components before proceeding.
8. 8

   Install new upper control arm to frame
   Position the new upper control arm at the front mounting point first, inserting the mounting bolt with any spacers or shims in their original positions. Thread the bolt but do not fully tighten. Install the rear mounting bolt with its hardware in the same manner. Thread but do not torque at this stage. Ensure the control arm moves freely through its range of motion.
9. 9

   Connect ball joint to steering knuckle
   Position the upper ball joint stud into the steering knuckle taper. Ensure the taper seats properly and fully. Install the castle nut or lock nut onto the ball joint stud. Tighten the nut firmly, ensuring the ball joint stud does not spin. If using a castle nut, align the slots with the cotter pin hole and install a new cotter pin.
10. 10

    Lower suspension to ride height
    Using the floor jack under the lower control arm, carefully raise or lower the suspension until it is at normal ride height position. This simulates the vehicle weight on the suspension and is the correct position for final torquing of control arm bolts. Do not torque suspension bushings in an unloaded position as this will cause premature bushing failure.
11. 11

    Torque control arm mounting bolts
    With the suspension at ride height, torque the front and rear upper control arm mounting bolts to manufacturer specifications. Without torque specs in the database, refer to the Rivian service manual for exact values. Typical upper control arm bolts on vehicles of this class range from 85-125 ft-lbs, but OEM specifications must be verified and followed.
12. 12

    Torque ball joint nut
    Torque the upper ball joint castle nut or lock nut to manufacturer specifications. Refer to the Rivian service manual for exact torque values. Verify that the ball joint stud does not rotate during torquing. If using a castle nut, ensure the cotter pin is properly installed and bent to secure the nut.
13. 13

    Reinstall wheel speed sensor components
    Reattach any wheel speed sensor wiring brackets or clips to the upper control arm or surrounding components. Ensure the wiring has adequate clearance and will not contact moving suspension parts or the tire during full suspension travel and steering input.
14. 14

    Reinstall wheel and lower vehicle
    Install the wheel and tire assembly onto the hub. Thread all lug nuts by hand to prevent cross-threading. Snug the lug nuts in a star pattern with a hand wrench. Lower the vehicle until the tire just contacts the ground. Torque the lug nuts to specification in a star pattern (typically 130-150 ft-lbs for this vehicle weight class, verify with Rivian specifications). Fully lower the vehicle and remove jack stands.

Reassembly

1. Verify all fasteners are properly torqued to specification
2. Confirm wheel speed sensor wiring is properly routed and secured
3. Check that no tools or parts were left in the wheel well or suspension area
4. Reconnect 12V battery negative terminal
5. Restore high voltage system per Rivian procedures if applicable

Verification

• Bounce the corner of the vehicle several times to settle the suspension and verify no unusual noises
• Perform a visual inspection of the upper control arm installation to confirm proper seating and alignment
• Test drive the vehicle at low speed in a safe area, checking for unusual noises, vibrations, or handling issues
• Schedule a professional wheel alignment immediately, as suspension geometry has been altered
• After alignment, verify steering wheel is centered and vehicle tracks straight
• Recheck all fastener torques after 50-100 miles of driving

More procedures for this vehicle