This procedure covers the removal and replacement of the front coil springs on a 2023 Rivian EDV 500 electric delivery van, requiring suspension disassembly and spring compression.

Warnings

Tools required

Parts

• Front coil spring (left or right as needed) × 1 — Use OEM specification - Rivian part number specific to EDV 500
• Upper strut mount bearing (if worn) × 1 — Inspect during disassembly
• Spring isolator/pad (upper and lower) × 2 — Replace if damaged
• Suspension hardware kit (lock nuts, bolts) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and engage parking brake firmly
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal and isolate the cable
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Raise front of vehicle using floor jack at manufacturer-specified lift points
6. Support vehicle securely on jack stands rated for commercial vehicle weight at proper frame support points
7. Remove front wheel completely
8. Spray all suspension fasteners with penetrating oil and allow to soak for 15-20 minutes
9. Visually inspect high-voltage components and orange cables - ensure no damage is present before proceeding
10. Take photos of suspension assembly for reference during reassembly

Procedure

1. 1

   Remove brake caliper and rotor
   Remove brake caliper mounting bolts and support caliper with wire or bungee cord - do not let it hang by the brake hose. Remove brake rotor to gain access to suspension components and reduce weight on the assembly.
2. 2

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor on the steering knuckle. Disconnect the electrical connector by pressing the release tab. Remove any mounting clips or brackets securing the sensor wire to prevent damage during disassembly.
3. 3

   Disconnect outer tie rod end
   Remove the castle nut from the outer tie rod end. Use a tie rod end puller or pickle fork to separate the tie rod from the steering knuckle. Count and record the number of threads visible on the tie rod for approximate alignment reference during reassembly.
   ⚠Using a pickle fork will likely destroy the tie rod end boot. Have replacement parts available if using this method.
4. 4

   Disconnect lower ball joint
   Remove the lower ball joint pinch bolt or castle nut (depending on design). Use a ball joint separator tool to disconnect the lower control arm from the steering knuckle. Apply steady pressure with the tool while tapping the knuckle boss with a hammer to break the taper loose.
5. 5

   Support lower control arm
   Position a floor jack under the lower control arm, close to the ball joint mounting point. Raise jack until it just begins to take the weight of the control arm. This will support the suspension load before removing upper mounting components.
   ⚠️The spring is compressed at this point. The jack is now holding significant stored energy. Ensure the jack is stable and positioned correctly.
6. 6

   Remove upper strut mounting nuts
   Access the upper strut mount from under the hood. Remove the protective cover if present. Locate the three upper strut mounting nuts. Hold the strut shaft center nut with a wrench to prevent spinning, then remove the three perimeter mounting nuts. Do NOT remove the center strut shaft nut at this time.
   ⚠️Do not remove the center strut shaft nut while the spring is under compression. This nut retains the compressed spring and removing it can cause violent spring release.
7. 7

   Lower and remove strut assembly
   Carefully lower the floor jack supporting the lower control arm. Guide the strut assembly downward and out from the wheel well. The assembly should come out as a complete unit with spring still compressed on the strut. If resistance is felt, check for any remaining connections.
8. 8

   Install spring compressor tool
   Place the strut assembly in a secure vice or strut holding fixture. Install the coil spring compressor tool according to manufacturer instructions, ensuring the compressor hooks engage at least three full coils on opposite sides of the spring for balanced compression. Verify the tool is properly seated before proceeding.
   ⚠️This is the most critical safety step. Improperly installed spring compressors can slip and release the spring violently. Double-check all hook engagement and alignment before tightening.
9. 9

   Compress spring and remove strut shaft nut
   Gradually tighten the spring compressor tool evenly, alternating sides to maintain balanced compression. Compress the spring until tension is relieved from the upper strut mount (you should see visible gap between mount and spring). Hold the strut shaft with a wrench and remove the center shaft nut. Remove the upper mount, bearing plate, and spring seat.
   ⚠️Ensure spring is fully compressed and no tension remains on the upper mount before removing the shaft nut. Keep hands and body clear of spring ends.
10. 10

    Remove old spring and decompress tool
    With the shaft nut removed, carefully slide the old coil spring off the strut body while still compressed in the tool. Move to a clear work area. Slowly and evenly release the spring compressor tension, alternating sides. Once fully decompressed, remove the compressor tool from the old spring.
11. 11

    Compress new spring
    Inspect the new coil spring for any shipping damage or defects. Install the spring compressor tool on the new spring in the same configuration used for the old spring. Compress the new spring gradually and evenly until it is compressed to approximately the same length as the old spring was when removed from the strut.
    ⚠️Ensure the spring compressor is properly engaged on the new spring. New springs may have different coatings that can be more slippery.
12. 12

    Install new spring on strut
    Install new lower spring isolator/pad on the strut lower spring seat if applicable. Slide the compressed new spring onto the strut body, ensuring the spring end properly seats in the lower spring seat groove or locating tab. Verify correct spring orientation - spring ends are typically formed to fit specific seat profiles.
13. 13

    Reassemble strut components
    Install the upper spring seat and bearing plate (replace bearing if worn during original disassembly). Install the upper strut mount. Thread on a new self-locking strut shaft nut and tighten while holding the shaft with a wrench. Tighten to manufacturer specifications (typically 50-70 ft-lb, but verify for this vehicle).
    ℹ️Without factory torque specifications in the database, conservative tightening is recommended. The nut should be tight enough to fully compress the mount bushing but not overtightened. Consult Rivian service documentation if available.
14. 14

    Release spring compressor
    Slowly and evenly release the spring compressor tool tension, alternating between adjustment points. Verify the spring properly seats in both upper and lower spring seats as tension is released. Once fully released and spring is fully seated, remove the compressor tool completely.
15. 15

    Reinstall strut assembly
    Lift the complete strut assembly back into position in the wheel well. Align the upper mounting studs with the holes in the strut tower. Install the upper mounting nuts finger-tight. Raise the floor jack under the lower control arm to align the ball joint with the steering knuckle, then reconnect and secure the ball joint connection. Install and tighten all fasteners to specification.

Reassembly

1. Reconnect the outer tie rod end to the steering knuckle - align to previously recorded thread count position
2. Tighten all suspension fasteners to manufacturer specifications using a calibrated torque wrench
3. Install new lock nuts where specified by manufacturer (typically strut shaft nut and ball joint nuts)
4. Reconnect ABS wheel speed sensor electrical connector and secure wiring with clips
5. Reinstall brake rotor and caliper - tighten caliper mounting bolts to specification
6. Reinstall wheel and hand-tighten lug nuts
7. Lower vehicle to ground and perform final tightening of lug nuts in star pattern to specification (typically 130-150 ft-lb for commercial vehicle)
8. Reconnect 12V battery negative terminal
9. Repeat entire procedure for opposite side if replacing both springs

Verification

• Before driving, bounce each corner of the vehicle several times to settle the suspension and ensure proper spring seating
• Start vehicle and verify no warning lights are present on instrument cluster
• Perform a careful test drive at low speed in a safe area - listen for any abnormal noises from front suspension
• Check for proper steering return to center and no pulling to either side
• Inspect all suspension fasteners for proper tightness after test drive
• Schedule a professional front-end alignment immediately - spring replacement affects camber, caster, and toe settings
• After 50-100 miles, re-inspect all suspension fasteners and re-torque if necessary
• Verify no leaks from brake system after caliper reinstallation

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