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

Warnings

Tools required

Parts

• Upper ball joint × 1 — Use OEM Rivian specification
• Cotter pin × 1 — Use OEM specification
• Castle nut (if not reusable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Disable high-voltage system following Rivian safety procedures
4. Loosen wheel lug nuts while vehicle is on ground
5. Lift front of vehicle and support on jack stands at manufacturer-specified lift points
6. Remove front wheel on affected side
7. Inspect upper ball joint for wear, play, or torn boot to confirm replacement is necessary

Procedure

1. 1

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

   Remove brake caliper and rotor assembly
   Remove brake caliper mounting bolts and secure caliper to frame or suspension with wire or bungee cord to avoid stressing brake hose. Remove brake rotor if necessary to access upper control arm fasteners. Do not let caliper hang by brake hose.
3. 3

   Disconnect wheel speed sensor
   Locate ABS wheel speed sensor wire routing near upper control arm. Disconnect electrical connector and unclip sensor wire from any brackets that may interfere with control arm removal or ball joint access.
4. 4

   Remove upper ball joint cotter pin and castle nut
   Locate the upper ball joint stud where it connects to the steering knuckle. Remove and discard the cotter pin. Using a breaker bar and socket, loosen and remove the castle nut from the ball joint stud. Do not reuse the cotter pin.
5. 5

   Separate ball joint from steering knuckle
   Use a ball joint separator tool or pickle fork to break the taper fit between the ball joint stud and steering knuckle. Insert tool between knuckle and control arm, then strike firmly or use press-type separator. Avoid damaging knuckle or control arm surfaces. If the ball joint spins, use a hex key or Torx bit in the stud top while applying separation force.
6. 6

   Access upper control arm bolts
   Depending on ball joint design, you may need to disconnect the upper control arm from the frame to access the ball joint mounting. Remove upper control arm mounting bolts at the frame pivot points. Support the control arm as fasteners are removed to prevent sudden movement.
7. 7

   Remove upper ball joint from control arm
   If ball joint is pressed into control arm: Position control arm in ball joint press with receiving cup underneath and press ram on top of ball joint body. Apply steady pressure to press ball joint out of control arm bore. If ball joint is bolted to control arm: Remove mounting bolts and separate ball joint from arm.
8. 8

   Clean control arm bore and inspect
   Thoroughly clean the ball joint mounting bore in the upper control arm using wire brush and solvent. Remove all rust, debris, and old grease. Inspect bore for damage, cracks, or excessive wear. Check control arm for bending or structural damage. Replace control arm if damage is found.
9. 9

   Install new upper ball joint
   If pressed design: Align new ball joint squarely in control arm bore with stud facing correct direction. Use ball joint press to install new joint, ensuring it seats fully against shoulder in bore. Press evenly to avoid cocking the joint. If bolted design: Position new ball joint and install mounting bolts, tightening in star pattern.
10. 10

    Reinstall upper control arm to frame
    Position upper control arm with new ball joint into frame mounting location. Install control arm mounting bolts finger-tight. Do not fully tighten mounting bolts until vehicle weight is on suspension at ride height.
11. 11

    Connect ball joint to steering knuckle
    Align ball joint stud with tapered hole in steering knuckle. You may need to adjust floor jack under lower control arm to align components. Insert stud through knuckle and install new castle nut. Tighten castle nut to specification (consult Rivian service data). Align nearest castle nut slot with cotter pin hole and install new cotter pin. Bend cotter pin ends to secure.
12. 12

    Reconnect wheel speed sensor and brake components
    Reconnect ABS wheel speed sensor electrical connector and secure wire routing to brackets. Reinstall brake rotor if removed. Position brake caliper over rotor and install caliper mounting bolts, tightening to specification.
13. 13

    Lower vehicle to load suspension
    Reinstall wheel and hand-tighten lug nuts. Lower vehicle until suspension is at normal ride height but wheels are not fully supporting vehicle weight. Torque upper control arm frame mounting bolts to specification with suspension loaded. This ensures proper bushing alignment.
14. 14

    Final torque and lower vehicle
    Remove floor jack from under lower control arm. Lower vehicle completely to ground. Torque wheel lug nuts to specification in star pattern. Re-enable high-voltage system following Rivian procedures.

Reassembly

1. All fasteners must be torqued to Rivian specifications - consult official service documentation as torque values are not available in this database
2. Control arm mounting bolts must be torqued at ride height to prevent premature bushing failure
3. Always use new cotter pins - never reuse
4. Verify ball joint boot is not torn or damaged during installation

Verification

• With vehicle on ground, grasp tire at top and bottom and attempt to rock it - there should be no play or clunking from upper ball joint
• Perform visual inspection of ball joint boot for proper seating and no tears
• Turn steering lock-to-lock to verify full range of motion without binding or interference
• Test drive vehicle at low speed and verify no abnormal noises from suspension
• Schedule four-wheel alignment immediately after ball joint replacement to ensure proper tire wear and handling
• Verify ABS wheel speed sensor is functioning properly with no warning lights

More procedures for this vehicle