Wheel Bearing Hub - Front

This procedure covers the removal and replacement of the front wheel bearing hub assembly on a 2022 Rivian EDV 500 electric delivery van with dual motor AWD.

Warnings

Tools required

Parts

• Front wheel bearing hub assembly × 1 — Use OEM Rivian specification
• Axle nut (new) × 1 — Use OEM specification
• Cotter pin × 1 — Match OEM diameter and length
• ABS sensor O-ring (if equipped) × 1 — Use OEM specification

Preparation

1. Place vehicle in service mode following manufacturer procedures to disable high-voltage systems
2. Chock rear wheels securely
3. Loosen front axle nut while vehicle is on ground (but do not remove)
4. Loosen front wheel lug nuts while vehicle is on ground
5. Raise vehicle and support on jack stands at manufacturer-specified lift points
6. Remove front wheel and tire assembly
7. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove ABS wheel speed sensor
   Locate the ABS wheel speed sensor on the back of the steering knuckle. Disconnect the electrical connector by pressing the release tab. Remove the sensor mounting bolt and carefully extract the sensor from the hub. Do not pull on the wiring harness. Inspect the sensor for damage and clean the mounting bore.
   Torque spec

   ABS Sensor Bolt10 Nm (7 lb-ft)
2. 2

   Remove brake caliper and bracket
   Remove the two brake caliper bracket bolts from the back of the steering knuckle. Support the caliper assembly with a wire hook or bungee cord to prevent strain on the brake hose. Do not let the caliper hang by the brake line. Remove the caliper bracket from the knuckle.
   ⚠Do not depress the brake pedal with the caliper removed or the pistons may extend and require bleeding.
   Torque spec

   Brake Caliper Bracket Bolts120 Nm (88 lb-ft)
3. 3

   Remove brake rotor
   If equipped with rotor set screws, remove them. If the rotor is stuck, use a rubber mallet to tap it free from the hub face. Do not strike the rotor with a steel hammer as this may damage it. Set the rotor aside on a clean surface.
4. 4

   Remove axle nut
   Have an assistant apply the brakes or use a pry bar to prevent the axle from rotating. Remove the cotter pin from the axle nut by straightening the ends and pulling it out with pliers. Remove the axle nut completely and discard it (a new nut will be installed). Mark the axle shaft position relative to the hub with a paint pen if desired for reference.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
5. 5

   Separate outer tie rod end
   Remove the outer tie rod end castle nut. Use a ball joint separator or pickle fork to separate the tie rod end from the steering knuckle. Be careful not to damage the tie rod boot. If reusing the tie rod end, avoid striking it directly with a hammer.
   ⚠Mark the tie rod position before removal to maintain approximate alignment settings.
6. 6

   Separate lower ball joint
   Remove the lower ball joint pinch bolt or castle nut (depending on configuration). Use a ball joint separator to disconnect the lower control arm from the steering knuckle. Support the lower control arm to prevent it from dropping suddenly. Note the orientation of any alignment shims or eccentric bolts for reassembly.
   ⚠The suspension will drop when the ball joint is separated. Ensure the area is clear and support the control arm.
7. 7

   Remove axle shaft from hub
   Push the axle shaft through the hub assembly using hand pressure. If the shaft is stuck, use a brass drift punch and hammer to tap it through from the back side. Do not strike the threads directly. Once free, support the outer end of the axle shaft with a bungee cord or wire to prevent damage to the inner CV joint boot.
   ⚠Do not allow the axle shaft to hang unsupported as this can damage the inner CV joint or differential seals.
8. 8

   Remove wheel bearing hub bolts
   Access the wheel bearing hub mounting bolts from the back side of the steering knuckle (4-5 bolts typically). Use a socket and breaker bar to remove all hub mounting bolts. Note the location of any washers or spacers behind the bolts. Keep fasteners organized for inspection.
   Torque spec

   Wheel Bearing Hub Bolts110 Nm (81 lb-ft)
9. 9

   Remove hub assembly from knuckle
   With all bolts removed, pull the hub assembly straight out from the front of the steering knuckle. If the hub is stuck, tap it gently from behind using a copper drift punch through the bolt holes. Do not pry against the ABS tone ring or bearing seals. Remove the hub and inspect the knuckle bore for damage or corrosion.
10. 10

    Clean and inspect mounting surfaces
    Use a wire brush to thoroughly clean the hub mounting face on the steering knuckle, removing all rust, dirt, and old thread locker. Clean the bolt holes with a tap if necessary. Inspect the knuckle bore for cracks, excessive wear, or damage. Clean the axle shaft splines with a wire brush and inspect for wear or damage. Apply a thin coat of anti-seize to the axle splines.
11. 11

    Install new wheel bearing hub assembly
    Apply a thin layer of anti-seize to the outer diameter of the new hub where it contacts the knuckle bore (avoid getting compound on the mounting face or bolt holes). Align the new hub with the axle shaft splines and guide it into the knuckle bore. Ensure the ABS tone ring is correctly oriented and the hub seats fully against the knuckle mounting face. Hand-thread all hub mounting bolts with threadlocker applied to the threads.
    ⚠Apply medium-strength threadlocker to hub bolt threads before installation. Verify all bolts are started before torquing.
    Torque spec

    Wheel Bearing Hub Bolts110 Nm (81 lb-ft)
12. 12

    Torque hub mounting bolts
    Torque all wheel bearing hub mounting bolts to specification in a star pattern to ensure even seating. Make two passes: first to 50% torque, then to final specification. Verify the hub rotates freely without binding after torquing.
    Torque spec

    Wheel Bearing Hub Bolts110 Nm (81 lb-ft)
13. 13

    Reinstall ABS sensor
    Inspect the ABS sensor bore in the hub and clean if necessary. Install a new O-ring on the sensor if equipped. Apply a small amount of anti-seize to the sensor body (not the tip). Insert the sensor into the hub and install the mounting bolt, torquing to specification. Reconnect the electrical connector. Verify proper clearance between the sensor tip and tone ring.
    ⚠Do not overtighten the ABS sensor bolt as this may damage the sensor or strip the threads in the aluminum hub.
    Torque spec

    ABS Sensor Bolt10 Nm (7 lb-ft)
14. 14

    Reinstall suspension and steering components
    Reconnect the lower ball joint to the steering knuckle and install the fastener. Reconnect the outer tie rod end and install the castle nut. Torque all fasteners to specification. Install new cotter pins where applicable. Ensure all suspension components are properly seated and aligned.
15. 15

    Install axle nut and final assembly
    Install the new axle nut onto the axle shaft. Have an assistant apply the brakes or use a pry bar to prevent rotation. Torque the axle nut to specification using a calibrated torque wrench. Install a new cotter pin through the axle shaft and bend the ends to secure. Reinstall the brake rotor, caliper bracket, and caliper assembly. Torque the caliper bracket bolts to specification. Install the wheel and tire assembly, then lower the vehicle. Perform final torque on lug nuts in a star pattern with the vehicle on the ground.
    ⚠️The axle nut is a critical fastener. Use a calibrated torque wrench and verify proper torque. Ensure the cotter pin is properly installed.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)

    Brake Caliper Bracket Bolts120 Nm (88 lb-ft)

Reassembly

1. Verify all fasteners are torqued to specification
2. Ensure the ABS sensor connector is properly seated and secured
3. Check that no tools or parts were left in the wheel well
4. Verify the axle nut cotter pin is properly installed and bent
5. Pump the brake pedal several times to ensure proper caliper piston position before driving

Verification

• Spin the wheel hub by hand to verify smooth rotation with no binding or noise
• Check for any play in the hub by grasping the tire at 12 and 6 o'clock positions and attempting to rock it
• Perform a test drive at low speed in a safe area, listening for any unusual noises from the wheel bearing
• Verify the ABS warning light does not illuminate on the dashboard
• Check for proper brake operation before returning vehicle to service
• Schedule a professional alignment check as suspension components were disturbed
• After 50-100 miles, re-torque the axle nut and wheel lug nuts to specification

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