This procedure covers the removal and replacement of the front ABS wheel speed sensor on a 2023 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Front ABS wheel speed sensor × 1 — Use OEM specification
• Wheel speed sensor mounting bolt × 1 — Use OEM specification if damaged
• Sensor wire harness clips × 2 — Replace if damaged during removal

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Ensure vehicle is powered off and key fob is at least 15 feet away
4. Safely lift and support the vehicle using proper lift points or jack stands
5. Remove the front wheel on the side requiring sensor replacement using proper lug nut pattern
6. Connect scan tool to retrieve and document any existing ABS fault codes

Procedure

1. 1

   Locate the wheel speed sensor
   With the wheel removed, locate the ABS wheel speed sensor mounted to the steering knuckle near the brake rotor. The sensor will have a single electrical connector and mounting bolt. Note the sensor wire routing for reinstallation.
2. 2

   Disconnect sensor electrical connector
   Follow the sensor wire harness toward the wheel well. Locate the electrical connector approximately 12-18 inches from the sensor. Press the connector release tab and carefully separate the connector halves. If corroded, gently wiggle while pulling to avoid damaging connector pins.
3. 3

   Remove wire harness routing clips
   Trace the sensor wire from the connector to the sensor. Remove any plastic routing clips or retainers securing the wire to the suspension components, brake line brackets, or frame. Use trim panel tools if necessary to avoid breaking clips. Note the exact routing path and clip locations for reinstallation.
4. 4

   Remove sensor mounting bolt
   Using a 10mm socket, remove the single bolt securing the wheel speed sensor to the steering knuckle. If the bolt is corroded or difficult to remove, apply penetrating oil and allow several minutes to soak. Keep the bolt unless damaged or corroded.
5. 5

   Extract the sensor from knuckle
   Carefully pull the sensor straight out from the steering knuckle bore. The sensor may be tight due to corrosion or debris buildup. If stuck, gently rotate the sensor body while pulling. Do not pry against the sensor tip or use excessive force. If extremely stuck, apply penetrating oil around the sensor body and wait before attempting removal again.
6. 6

   Clean sensor mounting bore
   Once the old sensor is removed, inspect the mounting bore in the steering knuckle. Use a wire brush or contact cleaner to remove any rust, corrosion, or debris from the bore. Ensure the bore is clean and smooth to allow proper seating of the new sensor and accurate air gap.
7. 7

   Inspect tone ring
   Visually inspect the ABS tone ring on the CV axle or hub assembly for damage, missing teeth, metal debris, or excessive rust. The tone ring must be clean and undamaged for proper sensor operation. Clean with contact cleaner if dirty but do not use abrasive materials that could damage teeth.
8. 8

   Prepare new sensor
   Remove the new wheel speed sensor from packaging. Verify part number matches application. Check that the sensor tip is clean and undamaged. Apply a light coat of dielectric grease to the sensor body O-ring area if present to aid installation and future removal.
9. 9

   Install new sensor
   Carefully insert the new sensor straight into the steering knuckle bore, ensuring proper alignment. Push the sensor fully into the bore until it seats completely. The sensor should sit flush with the mounting surface. Do not force or cock the sensor at an angle during installation.
10. 10

    Install sensor mounting bolt
    Insert the mounting bolt through the sensor mounting tab and thread into the steering knuckle. Tighten the bolt securely. Note: Specific torque specification not available in database; tighten to manufacturer specification if available, or to 8-10 ft-lbs typical for this application. Do not overtighten as this may crack the sensor housing.
11. 11

    Route sensor wire harness
    Route the sensor wire harness following the exact path noted during removal. Ensure the wire does not contact moving suspension components, the brake rotor, or CV axle. Maintain proper clearance from heat sources and sharp edges. Secure the wire using the original routing clips or new clips if originals were damaged.
12. 12

    Connect electrical connector
    Apply a small amount of dielectric grease to the sensor connector terminals if desired for corrosion protection. Align and connect the electrical connector halves, ensuring they fully seat with an audible click. Gently tug on the connector to verify it is locked.
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the front wheel, threading lug nuts by hand first. Torque lug nuts to manufacturer specification in a star pattern. Lower the vehicle to the ground and perform final lug nut torque verification.
14. 14

    Clear fault codes and test system
    Using the scan tool or Rivian diagnostic interface, clear any stored ABS fault codes. Perform a static system test if available through the diagnostic tool. Start the vehicle and verify the ABS warning light extinguishes after a few seconds. If the light remains on, retrieve and diagnose any new fault codes.

Reassembly

1. Ensure sensor wire harness is properly routed and secured with all clips installed
2. Verify electrical connector is fully seated and locked
3. Confirm wheel lug nuts are torqued to specification in proper sequence
4. Double-check that no tools or parts were left in the wheel well area

Verification

• Start vehicle and verify ABS warning light illuminates briefly then extinguishes
• Use scan tool to verify wheel speed sensor is providing signal and reading matches other sensors
• Perform a test drive at 5-10 mph and verify all four wheel speed sensors show active readings on scan tool
• Test drive at various speeds and verify ABS system functions normally with no warning lights
• If available, perform ABS self-test function through Rivian diagnostic interface to confirm proper operation

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