This procedure covers the removal and replacement of upper and lower ball joints on the front suspension of the 2023 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Upper ball joint (per side) × 2 — Use OEM specification
• Lower ball joint (per side) × 2 — Use OEM specification
• Upper ball joint castle nut (per side) × 2 — Use OEM specification
• Lower ball joint castle nut (per side) × 2 — Use OEM specification
• Cotter pins × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery negative terminal
4. Follow Rivian HV system lockout/tagout procedures to de-energize high-voltage system
5. Loosen front wheel lug nuts while vehicle is on ground
6. Raise front of vehicle and secure on jack stands at manufacturer-specified lift points
7. Remove both front wheels
8. Spray penetrating oil on ball joint fasteners and allow to soak for 10-15 minutes
9. Inspect suspension for any signs of damage that may complicate removal

Procedure

1. 1

   Remove brake caliper and rotor
   Remove brake caliper mounting bolts and secure caliper to frame with mechanic's wire to prevent strain on brake hose. Remove brake rotor to provide access to steering knuckle and ball joint area.
2. 2

   Disconnect stabilizer bar link
   Remove the stabilizer bar link from the control arm or steering knuckle. Use a wrench on the ball joint stud to prevent spinning while loosening the nut. Remove the link completely to provide working clearance.
3. 3

   Separate tie rod end from steering knuckle
   Remove the tie rod end castle nut and cotter pin. Use a tie rod separator or pickle fork to separate the tie rod end from the steering knuckle. Avoid damaging the tie rod boot during separation.
4. 4

   Remove upper ball joint castle nut
   Remove the cotter pin from the upper ball joint castle nut. Using a breaker bar and appropriate socket, remove the castle nut completely. Do not separate the ball joint taper yet. Note the orientation of the upper control arm for reassembly.
5. 5

   Remove lower ball joint castle nut
   Remove the cotter pin from the lower ball joint castle nut. Remove the lower ball joint castle nut completely. Keep upper and lower fasteners separated and labeled.
6. 6

   Separate ball joints from steering knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the upper ball joint taper from the steering knuckle. Support the steering knuckle with one hand. Next, separate the lower ball joint from the knuckle. Remove the steering knuckle assembly completely and set aside.
7. 7

   Remove upper ball joint from control arm
   Position the upper control arm in a secure vise or on the ball joint press. Install the appropriate ball joint press adapters around the upper ball joint. Apply pressure with the press to force the old ball joint out of the control arm. Clean the ball joint bore thoroughly with a wire brush and inspect for damage.
8. 8

   Remove lower ball joint from control arm
   Position the lower control arm in the ball joint press with proper support. Install the correct press adapters for the lower ball joint size. Press the old lower ball joint out of the control arm. Clean the ball joint bore and inspect for cracks, elongation, or other damage that would require control arm replacement.
9. 9

   Install new upper ball joint
   Position the new upper ball joint in the control arm bore ensuring proper orientation (grease fitting positioned correctly). Using the ball joint press with appropriate adapters, press the new ball joint into the control arm until it is fully seated. Verify the ball joint is flush with the control arm surface and not cocked.
10. 10

    Install new lower ball joint
    Position the new lower ball joint in the lower control arm bore with correct orientation. Press the new ball joint into place using the ball joint press until fully seated. Ensure the ball joint sits squarely in the bore and there are no gaps.
11. 11

    Install steering knuckle to ball joints
    Guide the steering knuckle over both the upper and lower ball joint studs simultaneously. It may be necessary to use a pry bar or jack to compress the suspension slightly for alignment. Install new castle nuts on both upper and lower ball joints finger-tight.
12. 12

    Torque ball joint castle nuts
    Torque the upper ball joint castle nut to Rivian specification (consult OEM documentation). Torque the lower ball joint castle nut to specification. If the cotter pin hole does not align, tighten further to the next castle slot - never loosen to align. Install new cotter pins and bend tabs to secure.
13. 13

    Reconnect tie rod end and stabilizer link
    Install the tie rod end into the steering knuckle and torque to specification. Install new cotter pin. Reconnect the stabilizer bar link to the control arm or knuckle and torque to specification.
14. 14

    Reinstall brake components and wheel
    Reinstall the brake rotor and caliper. Torque caliper mounting bolts to specification. Install the wheel and hand-tighten lug nuts. Repeat entire procedure for opposite side if necessary.
15. 15

    Final torque and system check
    Lower the vehicle to the ground. Torque wheel lug nuts to specification in a star pattern. Reconnect 12V auxiliary battery. Re-energize HV system following Rivian procedures. Pump brake pedal several times to ensure proper brake function before moving vehicle.

Reassembly

1. All fasteners must be torqued to OEM specifications - consult Rivian service documentation
2. New cotter pins must be installed on all ball joint castle nuts and tie rod ends
3. Ensure all suspension components move freely without binding
4. Verify brake caliper and rotor are properly secured before test driving

Verification

• Test drive vehicle at low speed in a safe area and listen for unusual noises from suspension
• Check for proper steering response with no looseness or wandering
• Verify no clicking, popping, or clunking sounds when turning or going over bumps
• Schedule four-wheel alignment immediately after ball joint replacement to prevent premature tire wear
• Inspect installation after 50-100 miles for any looseness or signs of improper installation
• Check that all cotter pins are properly installed and castle nuts are secure

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