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

Warnings

Tools required

Parts

• Front upper control arm bushing × 1 — Use OEM specification
• Upper ball joint nut (if damaged) × 1 — Use OEM specification
• Control arm mounting bolts (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack at designated jacking points
5. Support vehicle securely on jack stands rated for vehicle weight (approximately 6,000 lbs)
6. Remove front wheel and tire assembly completely
7. Spray all suspension fasteners with penetrating oil and allow to soak for 15-20 minutes
8. Mark the orientation of the control arm to the frame for reference during reinstallation

Procedure

1. 1

   Support the lower control arm
   Position a floor jack with a block of wood under the lower control arm to support the suspension. Raise the jack just enough to take the weight off the upper control arm but not to lift the vehicle. This prevents the suspension from dropping when the upper control arm is disconnected.
2. 2

   Disconnect the upper ball joint from the knuckle
   Remove the castle nut or retaining nut securing the upper ball joint to the steering knuckle. If a cotter pin is present, remove it first. Use a ball joint separator or pickle fork to separate the ball joint taper from the knuckle. Strike the separator firmly but avoid damaging the ball joint boot if reusing the control arm.
   ⚠The suspension may shift when the ball joint is separated. Ensure the lower control arm is properly supported.
3. 3

   Remove brake line and ABS sensor brackets
   Locate any brake line or ABS wheel speed sensor brackets attached to the upper control arm. Remove the mounting bolts or clips securing these brackets to the control arm. Position the brake line and sensor wire safely out of the way without placing tension on them.
4. 4

   Mark control arm position
   Before removing the control arm mounting bolts, use a paint pen or alignment tool to mark the exact position of the control arm relative to the frame mounting points. This will aid in reinstallation and minimize alignment changes.
5. 5

   Remove control arm mounting bolts
   Remove the front and rear bolts securing the upper control arm to the frame or suspension subframe. These bolts typically pass through the control arm bushings. Support the control arm as you remove the final bolt to prevent it from falling. Remove the control arm from the vehicle.
6. 6

   Inspect the control arm and bushing
   Examine the control arm for cracks, bends, or other damage. Inspect the bushing mounting area for corrosion or distortion. Clean the bushing bore thoroughly with a wire brush. Identify whether the bushing is a press-fit or bonded type.
7. 7

   Remove the old bushing
   Using a hydraulic press or control arm bushing press kit, press out the old bushing from the control arm. Position the control arm on the press bed with proper support, ensuring the bushing has clearance to exit. Apply steady, even pressure to avoid damaging the control arm. If the bushing is bonded, it may require cutting or specialized removal tools.
   ⚠Ensure the control arm is properly supported during pressing to prevent bending or cracking.
8. 8

   Clean the bushing bore
   After bushing removal, thoroughly clean the control arm bushing bore with a wire brush and solvent. Remove all rust, rubber residue, and debris. Inspect the bore for damage. If the bore is damaged or out-of-round, the control arm must be replaced.
9. 9

   Install the new bushing
   Apply a thin coat of soapy water or approved bushing lubricant to the new bushing outer diameter and the control arm bore (do not use petroleum-based lubricants). Align the bushing with the bore, ensuring any orientation marks or voids are positioned correctly per manufacturer specifications. Using the hydraulic press and appropriate adapters, press the new bushing into the control arm until it is fully seated and flush with the control arm housing.
10. 10

    Reinstall the control arm to the frame
    Position the control arm back into the vehicle, aligning it with the frame mounting points and the reference marks made during removal. Insert the front and rear mounting bolts through the bushings and frame brackets. Thread the bolts hand-tight but do not fully torque them yet. The suspension must be at ride height before final torquing.
11. 11

    Reconnect the upper ball joint
    Align the upper ball joint stud with the hole in the steering knuckle. Install the retaining nut and tighten hand-tight. If a castle nut is used, tighten to specification and install a new cotter pin through the castle nut slots and ball joint stud.
12. 12

    Reattach brake line and sensor brackets
    Reinstall any brake line brackets and ABS sensor wire brackets to the upper control arm. Ensure the brake line and sensor wire have proper routing with no kinks, tension, or contact with moving components.
13. 13

    Load the suspension and torque fasteners
    Remove the jack stands and lower the vehicle until the suspension is at normal ride height (tires on ground, vehicle weight on suspension). This is critical because control arm bushings must be torqued at ride height to prevent premature wear. With the suspension loaded, torque the control arm mounting bolts and ball joint nut to manufacturer specifications. Consult the Rivian service manual for exact torque values.
14. 14

    Reinstall the wheel and lower the vehicle
    Reinstall the wheel and tire assembly. Thread the lug nuts by hand, then tighten them in a star pattern. Lower the vehicle completely to the ground. Perform final torquing of the lug nuts to manufacturer specification (typically 120-150 ft-lb for this vehicle class) in a star pattern.

Reassembly

1. Ensure all suspension fasteners have been torqued to specification with the suspension at ride height
2. Verify brake lines and ABS sensor wires are properly secured and routed
3. Check that no tools or parts have been left in the wheel well or suspension area
4. Perform a visual inspection of all work completed

Verification

• Test drive the vehicle at low speed in a safe area, listening for any unusual noises from the front suspension
• Check for proper steering response and control
• Verify there are no rattles, clunks, or abnormal handling characteristics
• Schedule a professional wheel alignment immediately, as suspension work has altered the alignment settings
• After 50-100 miles, recheck all fastener torque values to ensure nothing has loosened

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