This procedure covers the removal and replacement of the lower ball joint on a 2023 Rivian EDV 500 delivery van with dual motor AWD configuration.

Warnings

Tools required

Parts

• Lower ball joint assembly × 1 — Use OEM Rivian specification
• Ball joint retaining hardware kit × 1 — Use OEM specification
• Cotter pin (if applicable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind wheels opposite to the side being serviced
3. If available, deactivate high-voltage system following Rivian lockout/tagout procedure
4. Loosen wheel lug nuts while vehicle is on ground (do not remove)
5. Raise vehicle using floor jack at manufacturer-specified lift point
6. Support vehicle with heavy-duty jack stands rated for EV weight at designated support points
7. Remove wheel and tire assembly completely
8. Spray all suspension fasteners with penetrating oil and allow to soak for 15 minutes
9. Photograph suspension assembly orientation before disassembly for reference

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the suspension. Raise jack slightly to compress the suspension and relieve load on the ball joint. This prevents the control arm from dropping suddenly when the ball joint is separated.
2. 2

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and suspend the caliper with wire or a bungee cord to avoid stressing the brake hose. Do not let the caliper hang by the brake line. Remove the brake rotor by pulling it off the hub. If stuck, use gentle tapping with a rubber mallet on the back side.
3. 3

   Disconnect wheel speed sensor
   Locate the ABS wheel speed sensor connector near the steering knuckle. Disconnect the electrical connector and carefully route the sensor wire clear of the work area. Note the wire routing for reinstallation.
4. 4

   Remove steering knuckle to ball joint connection
   Locate the ball joint castle nut or pinch bolt connecting the lower ball joint to the steering knuckle. If equipped with a castle nut, remove the cotter pin and discard it. Remove the castle nut or pinch bolt fastener completely. Mark the orientation if using a pinch bolt design.
5. 5

   Separate ball joint from steering knuckle
   Use a ball joint separator tool or pickle fork to separate the ball joint taper from the steering knuckle. Position the separator between the control arm and knuckle, then strike or press to break the taper fit. Avoid damaging the ball joint boot if reusing any components. Once separated, support the knuckle assembly to prevent it from falling.
6. 6

   Remove ball joint retaining fasteners
   Locate the ball joint mounting bolts or rivets securing the ball joint to the lower control arm. If using bolts, remove them completely using the appropriate socket and breaker bar. If original equipment uses rivets, drill them out using a drill bit slightly larger than the rivet shaft, being careful not to damage the control arm mounting holes.
7. 7

   Extract the lower ball joint
   If the ball joint is pressed into the control arm, use a ball joint press tool with the appropriate adapters to press the old ball joint out of the control arm bore. Apply pressure gradually and ensure the tool is aligned properly to prevent damaging the control arm. If bolted, simply remove the ball joint once all fasteners are removed.
8. 8

   Clean and inspect control arm mounting area
   Use a wire brush to thoroughly clean the ball joint mounting area on the control arm. Inspect the mounting bore or surface for cracks, deformation, or excessive wear. Check control arm bushings for deterioration. Replace the control arm if any damage is found. Apply a thin coat of anti-seize to the ball joint bore if pressed-fit type.
9. 9

   Install new lower ball joint
   Position the new ball joint into the control arm mounting location. For pressed-fit joints, use the ball joint press with correct adapters to press the new joint into place until fully seated. Ensure the ball joint is oriented correctly with the stud pointing in the proper direction. For bolt-in types, align the new ball joint and start all mounting bolts by hand before tightening.
10. 10

    Secure ball joint retaining hardware
    Install new ball joint mounting bolts and washers per manufacturer specifications. Tighten fasteners in a cross pattern if multiple bolts are used. Note: Without OEM torque specifications, do not complete final torque at this time. Hand-tighten plus moderate wrench pressure only until OEM specs are obtained.
11. 11

    Connect ball joint to steering knuckle
    Lower the steering knuckle assembly onto the ball joint stud. Ensure the taper seats fully into the knuckle bore. Install the castle nut or pinch bolt and tighten hand-tight initially. For pinch bolt designs, ensure proper alignment of the knuckle split.
12. 12

    Torque knuckle connection
    Using a torque wrench, tighten the ball joint castle nut or pinch bolt to manufacturer specification (specification not available in database - consult Rivian service documentation). For castle nuts, tighten to specification and advance only as needed to align cotter pin hole. Install new cotter pin and bend tabs to secure.
13. 13

    Reinstall brake components
    Reinstall the brake rotor onto the hub, ensuring it seats flush. Position the brake caliper over the rotor and install caliper mounting bolts. Reconnect the wheel speed sensor connector and secure the sensor wire using original routing and clips. Verify the sensor sits properly in its mounting hole with correct air gap.
14. 14

    Final suspension check
    Slowly lower the floor jack supporting the control arm to allow suspension to return to normal ride height while still on jack stands. Visually inspect all connections and verify no interference between components through full suspension travel. Gently cycle the suspension by hand to check for binding or unusual noises.

Reassembly

1. Reinstall wheel and tire assembly, starting lug nuts by hand
2. Lower vehicle partially so tire contacts ground but weight is still on jack stands
3. Torque wheel lug nuts to manufacturer specification in a star pattern
4. Remove jack stands and lower vehicle completely to ground
5. Perform final torque check on all suspension fasteners once OEM specifications are obtained
6. If available, use Rivian diagnostic tool to clear any suspension-related fault codes
7. Road test vehicle at low speed in a safe area to verify proper operation before returning to service

Verification

• Verify no unusual noises from suspension during steering or driving over bumps
• Check that steering returns to center properly and feels normal
• Perform visual inspection underneath vehicle for any loose fasteners or components
• Verify wheel speed sensor is functioning properly (no ABS warning lights)
• Schedule immediate professional alignment as ball joint replacement affects suspension geometry
• Monitor the repair area for the first 50 miles of operation for any unusual symptoms
• Verify all high-voltage systems were properly reactivated if they were disabled during service

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