This procedure covers the removal and replacement of the front lower control arm bushings on a 2023 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Front lower control arm bushing kit (left) × 1 — Use OEM specification
• Front lower control arm bushing kit (right) × 1 — Use OEM specification
• Control arm mounting hardware kit × 1 — Use OEM specification if replacing

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 and wait 2 minutes
4. Enable service mode through vehicle interface to disable high voltage system
5. Loosen front wheel lug nuts while vehicle is on ground
6. Raise front of vehicle and support on jack stands at manufacturer-specified lift points
7. Remove front wheels completely
8. Spray all suspension fasteners with penetrating lubricant and allow to soak
9. Mark alignment position of adjustable components with paint pen for reference

Procedure

1. 1

   Remove lower skid plate and underbody panels
   Remove the front underbody protective panels to access the front suspension components. Remove fasteners securing skid plates and set aside for reinstallation. On the EDV 500, there are typically 12-16 fasteners securing the forward skid plate section.
2. 2

   Disconnect wheel speed sensor
   Locate the wheel speed sensor mounted near the lower control arm. Disconnect the electrical connector by pressing the locking tab and pulling straight out. Secure the sensor wire away from the work area using zip ties or wire to prevent damage.
3. 3

   Remove sway bar end link
   Support the lower control arm with a floor jack to prevent sudden movement. Remove the sway bar end link nut from the lower control arm attachment point. Use a hex key or second wrench to prevent the ball stud from spinning. Remove the end link from the control arm.
4. 4

   Disconnect lower ball joint
   Remove the castle nut or lock nut securing the lower ball joint to the steering knuckle. Remove the cotter pin if equipped. Use a ball joint separator tool to break the taper connection between the ball joint stud and knuckle. Do not strike the knuckle directly as this may damage ABS sensor components on the EDV's integrated hub assembly.
5. 5

   Support knuckle assembly
   Once the ball joint is separated, support the knuckle and hub assembly using a bungee cord or wire secured to the frame or upper control arm. Ensure the CV axle is not stressed or bent at extreme angles, as the EDV 500 uses constant velocity joints that can be damaged by overextension.
6. 6

   Remove rear control arm mounting bolt
   Locate the rear bushing mounting bolt that secures the control arm to the subframe or chassis. This is typically a large diameter bolt through the bushing sleeve. Use a breaker bar to loosen the bolt while supporting the control arm with a jack. Remove the bolt completely and note the orientation of any washers or spacers.
7. 7

   Remove front control arm mounting bolt
   Locate and remove the front bushing mounting bolt in the same manner as the rear. The control arm should now be free to remove from the vehicle. Lower the jack supporting the control arm and carefully extract the arm from the suspension bay, noting the routing of any brackets or components.
8. 8

   Press out old bushings
   Secure the control arm in a vise or on a stable work surface. Using a hydraulic press or control arm bushing press kit, carefully press out the old bushings from the control arm. Note the orientation of the bushings, particularly any offset or directional design features. The EDV control arms may use bonded bushings that require cutting the outer sleeve before pressing.
9. 9

   Clean control arm bushing bores
   Use a wire brush to thoroughly clean the bushing bores in the control arm, removing all rust, old rubber debris, and corrosion. Inspect the bores for damage, cracks, or elongation. If damage is present, the entire control arm must be replaced. Clean the mounting surfaces where the control arm contacts the chassis.
10. 10

    Install new bushings
    Apply a light coating of dish soap or bushing installation lubricant to the outer sleeve of the new bushings (do not use petroleum-based lubricants). Align the bushing with the bore, noting any orientation marks or offset designs. Using the press kit, carefully press the new bushing into the control arm bore until it is fully seated and flush with the control arm housing. Ensure the bushing is installed squarely and not cocked.
11. 11

    Reinstall control arm to chassis
    Position the control arm back into the suspension mounting points. Insert the front mounting bolt through the bushing and chassis bracket, but do not fully tighten yet. Install the rear mounting bolt through the bushing and chassis bracket. Thread both bolts by hand to ensure proper alignment. Suspension bushings should be torqued at normal ride height, so leave bolts snug but not fully tightened.
12. 12

    Reconnect lower ball joint
    Remove the support from the knuckle assembly and guide the lower ball joint stud into the steering knuckle. Install the castle nut or lock nut onto the ball joint stud and tighten. If using a castle nut, tighten to specification and install a new cotter pin through the stud. Ensure the ball joint is fully seated in the taper.
13. 13

    Reinstall sway bar end link
    Connect the sway bar end link to the lower control arm. Install the retaining nut and tighten while preventing the ball stud from spinning. Do not overtighten as this can damage the ball socket.
14. 14

    Final tightening of control arm bolts
    Lower the vehicle until the suspension is at normal ride height with the wheels just touching the ground (or use a jack under the control arm to simulate ride height loading). At this position, torque the front and rear control arm bushing mounting bolts to specification. This is critical as tightening bushings while suspension is hanging can cause premature bushing failure and binding.
15. 15

    Reconnect wheel speed sensor and reinstall underbody panels
    Reconnect the wheel speed sensor electrical connector ensuring it clicks into place. Verify the sensor wire is properly routed and secured away from moving suspension components. Reinstall all underbody panels and skid plates with all fasteners.

Reassembly

1. Install front wheels and hand-tighten lug nuts in a star pattern
2. Lower vehicle to ground and torque lug nuts to specification in star pattern
3. Reconnect 12V auxiliary battery negative terminal
4. Exit service mode through vehicle interface to restore high voltage system
5. Verify all warning lights extinguish on instrument cluster

Verification

• Test drive vehicle at low speed in a safe area and verify no abnormal noises, vibrations, or handling issues
• Verify wheel speed sensor operation through vehicle diagnostics or confirm ABS warning light is not illuminated
• Visually inspect all mounting bolts for proper installation and torque
• Schedule professional wheel alignment immediately as bushing replacement affects suspension geometry
• After 50-100 miles, re-inspect all fasteners for proper torque retention

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