This procedure replaces both front strut assemblies on the 2023 Rivian EDV 500 electric delivery van, including removal of wheels, brake lines, and suspension components.

Warnings

Tools required

Parts

• Front strut assembly, left × 1 — Use OEM Rivian specification
• Front strut assembly, right × 1 — Use OEM Rivian specification
• Strut mount hardware kit × 2 — Use OEM specification
• Brake line mounting clips × 4 — Replace as needed
• Self-locking nuts for strut mounting × 6 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Open hood and locate 12V battery in rear storage compartment via access panel
4. Disconnect 12V negative battery terminal and wait 5 minutes for systems to power down
5. Verify high-voltage system is in safe mode (consult owner's manual for indicator lights)
6. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
7. Lift front of vehicle using floor jack at manufacturer-specified front jacking points
8. Support vehicle on jack stands at designated support points behind front wheels on frame rails
9. Remove front wheels completely and set aside
10. Spray all suspension fasteners with penetrating oil and allow to soak 15 minutes
11. Take photos of brake line routing and ABS sensor wire routing for reference during reassembly

Procedure

1. 1

   Access upper strut mounting points
   Open the hood fully. Locate the strut towers in the engine bay near each front fender. Remove any plastic cowl covers or access panels covering the top of the strut mounts. You should see three mounting nuts securing the top of each strut assembly to the strut tower. Do not remove these nuts yet.
2. 2

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor on the back of the steering knuckle. Press the connector tab and disconnect the electrical connector. Unclip the sensor wire from any brackets along the strut body and lower control arm. Route the wire safely away from the work area to prevent damage.
3. 3

   Disconnect brake line from strut bracket
   Locate the brake line bracket mounted to the strut body. Using a brake line wrench, carefully loosen the brake line fitting if it is a hard connection, or remove the mounting clip if the line is only bracketed. If the line must be disconnected, have a container ready to catch brake fluid and immediately plug both ends. If line can remain connected but with slack, carefully route it away from strut assembly.
4. 4

   Remove sway bar end link from strut
   Locate the sway bar end link connecting the sway bar to the strut assembly lower bracket. Hold the ball joint stud with a hex key to prevent spinning. Remove the nut securing the end link to the strut bracket. If ball joint spins freely, use a ball joint separator to break the taper. Remove end link from strut and suspend from sway bar using wire to prevent stress on bushings.
5. 5

   Separate steering knuckle from strut
   Locate the two large bolts connecting the steering knuckle to the lower portion of the strut body (strut-to-knuckle pinch bolts). These are typically 18mm or 21mm bolts. Before removing, mark the position of the knuckle relative to the strut for camber reference. Remove both bolts completely. Use a pry bar to carefully spread the knuckle clamp and separate it from the strut. The knuckle assembly will remain hanging from the control arm and tie rod.
6. 6

   Support and remove strut assembly
   From under the vehicle, support the strut assembly with one hand or have an assistant hold it. Return to the engine bay and remove the three upper strut mount nuts from the strut tower. Carefully lower the strut assembly down and out through the wheel well. The strut and spring assembly will be heavy, approximately 25-30 lbs. Set it on a clean work surface.
7. 7

   Disassemble old strut (if reusing spring)
   If transferring the spring to a new strut, install a quality strut spring compressor on opposite sides of the coil spring per tool manufacturer instructions. Compress the spring evenly until there is no tension on the upper strut mount. Hold the strut shaft with a hex socket and remove the top shaft nut. Remove the upper mount, bearing plate, spring seat, and compressed spring. Keep all parts organized for transfer or replacement.
   ⚠️Spring is under extreme compression. Ensure spring compressors are properly seated and engaged before removing shaft nut. Stand to the side, never over the assembly.
8. 8

   Prepare new strut assembly
   If new strut assemblies are pre-assembled (complete with springs and mounts), skip to next step. If transferring components, install the compressed spring onto the new strut body, ensuring spring ends seat properly in the upper and lower spring seats. Install the bearing plate, upper mount, and new hardware. Hold the shaft with a hex socket and tighten the top nut to specification. Since no torque spec is provided in database, reference the OEM service manual for proper torque value. Carefully release spring compressors evenly.
9. 9

   Install new strut assembly into vehicle
   Lift the new strut assembly up through the wheel well, aligning the upper mounting studs with the holes in the strut tower. From the engine bay, start the three upper mounting nuts by hand. Snug them but do not fully tighten yet. Support the bottom of the strut while keeping the upper mount in position.
10. 10

    Connect steering knuckle to new strut
    Guide the lower portion of the strut into the steering knuckle clamp opening. Align the previously marked position for camber reference. Install both strut-to-knuckle pinch bolts and tighten evenly. Without torque specifications in database, consult Rivian service documentation for proper torque values. Ensure knuckle is fully seated against strut before final torquing.
11. 11

    Reconnect sway bar end link and brake components
    Reconnect the sway bar end link to the strut bracket. Install a new self-locking nut and torque per service manual specification while holding the ball stud with a hex key. Reattach the brake line to its bracket on the strut using a new clip or reconnect the brake line fitting if it was disconnected. Torque brake line fittings carefully to avoid stripping. Reclip ABS sensor wire to brackets along strut body.
12. 12

    Reconnect ABS sensor and finalize upper mounts
    Reconnect the ABS wheel speed sensor electrical connector ensuring it clicks fully into place. From the engine bay, fully tighten the three upper strut mount nuts in a star pattern to ensure even seating. Without specific torque values available, follow Rivian service manual specifications.
13. 13

    Repeat procedure for opposite side
    Repeat steps 2 through 12 for the opposite front strut assembly. Ensure all components are installed symmetrically and all fasteners are properly torqued.
14. 14

    Reinstall wheels and lower vehicle
    Reinstall both front wheels, starting lug nuts by hand. Lower vehicle from jack stands using floor jack until wheels just touch ground. Torque lug nuts to specification in a star pattern (typically 140-150 ft-lb for Rivian, but verify in owner's manual). Fully lower vehicle and remove jack.
15. 15

    Bleed brake system and reconnect battery
    If brake lines were disconnected, bleed the brake system starting with the right rear wheel, then left rear, right front, and left front until all air is purged and fluid runs clear. Top off brake fluid reservoir with DOT 4 fluid to proper level. Reconnect 12V battery negative terminal. Start vehicle and verify no warning lights related to brakes or suspension systems.

Reassembly

1. Ensure all electrical connectors for ABS sensors are fully seated and secured
2. Verify brake lines are properly routed and secured to prevent rubbing on tires or suspension components
3. Double-check that all fasteners have been reinstalled and torqued to specification
4. Reinstall any cowl covers or access panels removed from strut tower area

Verification

• With vehicle on level ground, bounce each front corner firmly several times to settle suspension, then verify no unusual noises or binding
• Start vehicle and verify no ABS, brake, or suspension warning lights are illuminated on dashboard
• Test brake pedal feel - it should be firm with no sponginess indicating air in lines
• Perform a careful test drive in a safe area at low speed, checking for unusual noises, vibrations, or pulling to one side
• Inspect all work areas for leaking brake fluid or loose components
• Schedule a professional four-wheel alignment immediately - do not drive vehicle extensively until alignment is completed
• After 50-100 miles, re-torque all suspension fasteners and verify tightness
• Monitor tire wear patterns over next 500 miles to confirm proper alignment

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