This procedure covers the replacement of wheel studs on the 2022 Rivian EDV 500, including removal of the wheel hub assembly, pressing out damaged studs, and installing new studs.

Warnings

Tools required

Parts

• Wheel stud (specify quantity per wheel) × 1 — Use OEM specification
• Wheel hub assembly (if damaged during removal) × 1 — Use OEM specification
• Axle nut (single-use) × 1 — Use OEM specification
• Brake caliper bracket bolts (if thread damage occurs) × 2 — Use OEM specification
• Hub assembly mounting bolts (if replacement needed) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and ensure it is in Park mode with ignition off
2. Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
3. If working on rear wheels, connect diagnostic software and activate electronic parking brake service mode
4. Loosen wheel lug nuts while vehicle is still on the ground
5. Raise vehicle with floor jack at designated lift points and support with heavy-duty jack stands rated for EV weight
6. Remove wheel and tire assembly
7. Inspect brake system and surrounding components for any damage that may have occurred with stud failure

Procedure

1. 1

   Remove brake caliper assembly
   Remove the brake caliper mounting bolts and carefully suspend the caliper from the suspension using a wire hanger or bungee cord. Do not allow caliper to hang by the brake hose. If working on rear brakes, ensure electronic parking brake actuator is in service mode to allow caliper removal.
2. 2

   Remove brake rotor
   Remove the brake rotor retaining screws if present. If rotor is seized to the hub, use a rubber mallet to tap around the hat section of the rotor to break it free. Do not strike the braking surface. For stubborn rotors, thread bolts into the threaded jacking holes if equipped.
3. 3

   Mark and remove axle nut
   Remove the center axle nut dust cap. The axle nut is a single-use fastener and must be replaced. Use a breaker bar and appropriate socket to remove the axle nut. This nut is torqued to very high specification and will require significant force to loosen. Have an assistant apply the brake pedal or use a hub holding tool to prevent rotation.
4. 4

   Disconnect ABS sensor and hub electrical connections
   Locate the ABS wheel speed sensor connector and any other electrical connections to the hub assembly. Carefully disconnect these connectors and secure wiring out of the work area. Note the routing for reinstallation.
5. 5

   Remove hub assembly mounting bolts
   Access the hub assembly mounting bolts from the back side of the steering knuckle or suspension mount. There are typically 4 bolts securing the hub assembly. Remove these bolts completely and retain for reinstallation if threads are in good condition.
6. 6

   Remove hub assembly from knuckle
   Using a hub puller or slide hammer with appropriate adapters, carefully extract the hub assembly from the steering knuckle or suspension mount. The hub may be press-fit and require significant force. Avoid damage to the knuckle bore surface. If the bearing is seized, apply penetrating oil and allow to soak, then retry removal.
7. 7

   Inspect hub assembly and stud damage
   With the hub removed, thoroughly inspect for damage to the hub flange, bearing surfaces, and stud mounting holes. Check for cracks, elongated stud holes, or bearing damage. If hub damage is present, the entire hub assembly must be replaced. Identify which studs require replacement.
8. 8

   Remove damaged wheel studs
   Using a hydraulic press or dedicated wheel stud press tool, press the damaged studs out from the back side of the hub flange. Position the hub flange on a support with an opening that allows the stud to pass through. Apply steady, even pressure to avoid damaging the hub. Alternatively, use a large hammer and brass drift to drive studs out, working carefully to avoid hub flange damage.
9. 9

   Clean stud mounting holes
   Clean the stud mounting holes in the hub flange thoroughly using a wire brush and appropriate solvent. Remove any rust, debris, or metal shavings. Inspect holes for elongation or damage. The holes must be clean and undamaged for proper stud installation and retention.
10. 10

    Install new wheel studs
    Insert new wheel studs into the hub flange from the back side. Ensure the serrated stud shoulder seats properly against the hub flange. Using a hydraulic press or stud installation tool, press each stud into position until the serrated shoulder is fully seated and flush against the hub face. Apply steady, even pressure. Verify stud is straight and fully seated by checking that the stud face is flush with surrounding studs.
11. 11

    Verify stud installation
    Inspect all newly installed studs to ensure they are properly seated, straight, and project the correct distance compared to original studs. The stud should not rotate in the hub. If a stud rotates, it must be pressed in further or the hub may be damaged requiring replacement.
12. 12

    Clean and prepare knuckle mounting surface
    Clean the hub mounting surface on the steering knuckle or suspension mount thoroughly. Remove any rust, old sealant, or debris. Apply a thin coat of anti-seize compound to the mounting surface and bolt threads to prevent future seizure.
13. 13

    Install hub assembly to knuckle
    Carefully align the hub assembly with the knuckle mounting surface and slide into position. Ensure proper alignment of bolt holes and that the hub seats fully. Install all hub mounting bolts and tighten in a star pattern to draw the hub in evenly. Follow manufacturer torque specifications if available, or tighten securely in stages.
14. 14

    Install new axle nut
    Install the new single-use axle nut onto the CV axle. Hand-tighten initially. The final torque will be applied with the wheel installed and vehicle on the ground to prevent bearing preload issues. Follow manufacturer torque specifications for final tightening.
15. 15

    Reinstall brake components and complete assembly
    Reinstall the brake rotor and secure with retaining screws if equipped. Reinstall the brake caliper assembly and torque mounting bolts to specification. Reconnect all electrical connectors including ABS sensor. Verify all connections are secure and properly routed. Install wheel and tire assembly, torquing lug nuts in a star pattern to manufacturer specification.

Reassembly

1. With vehicle back on the ground, torque the axle nut to manufacturer specification using a torque wrench
2. Install the axle nut dust cap
3. If rear brakes were serviced, exit electronic parking brake service mode using diagnostic software
4. Reconnect 12V battery negative terminal
5. Test electronic parking brake operation and verify proper function
6. Verify ABS warning light is not illuminated after system self-check

Verification

• Start vehicle and verify no warning lights related to ABS, traction control, or brake system are illuminated
• Test drive vehicle at low speed in a safe area and verify no unusual noises, vibrations, or handling issues
• Perform several moderate brake applications to verify proper brake function
• Re-check wheel lug nut torque after 50-100 miles of driving
• Visually inspect for any leaks or loose components around the wheel hub area
• Verify wheel rotates freely without binding or excessive play when raised off the ground

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