Procedure to remove and replace the front steering knuckle/spindle assembly on a 2023 Rivian EDV 500 electric delivery van with dual motor AWD.

Warnings

Tools required

Parts

• Front steering knuckle assembly × 1 — Use OEM specification
• Wheel hub assembly (if integrated) × 1 — Use OEM specification
• Lower ball joint pinch bolt × 1 — Use OEM specification
• Upper ball joint pinch bolt (if applicable) × 1 — Use OEM specification
• Tie rod end castle nut × 1 — Use OEM specification
• Axle nut × 1 — Use OEM specification
• Brake rotor mounting screws × 2 — Use OEM specification
• ABS sensor (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 2 minutes for system discharge
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise vehicle on lift or secure on jack stands at manufacturer-specified lift points
5. Remove front wheel from affected side
6. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes
7. Place drain pan under work area to catch any residual fluids

Procedure

1. 1

   Remove axle nut and brake caliper
   Have an assistant apply brakes or use a pry bar wedged against wheel studs to prevent hub rotation. Remove and discard the front axle nut using appropriate socket. Remove brake caliper mounting bolts and carefully hang caliper from suspension using wire or caliper hanger - do not allow caliper to hang by brake hose. Remove brake rotor and set aside.
2. 2

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor connector on the knuckle or nearby wiring harness. Disconnect the electrical connector by pressing the release tab. Remove the sensor mounting bolt and carefully extract the sensor from the knuckle bore. Inspect sensor tip for damage and clean if reusing.
3. 3

   Separate tie rod end from knuckle
   Remove the castle nut or lock nut securing the outer tie rod end to the steering knuckle. If a castle nut is used, remove cotter pin first. Use a tie rod end separator tool to press the tie rod stud out of the knuckle taper. Do not use excessive force with a hammer as this may damage the knuckle or tie rod end threads.
4. 4

   Disconnect upper control arm or strut mount
   Depending on front suspension design, either separate the upper ball joint from the knuckle by removing the pinch bolt or castellated nut, or remove the upper strut-to-knuckle bolts. Support the knuckle assembly from below before fully disconnecting. If ball joint is pressed into knuckle, note orientation for reassembly.
5. 5

   Separate lower ball joint from knuckle
   Remove the lower ball joint pinch bolt or castellated nut and cotter pin. Use a ball joint separator or pickle fork to separate the lower ball joint taper from the knuckle. Apply separating force carefully to avoid damaging the ball joint boot if reusing components. If pinch bolt design, spread the knuckle opening slightly if needed.
6. 6

   Remove drive axle from hub
   With the knuckle now free from suspension mounting points, carefully pull the knuckle assembly outward away from the vehicle. The CV axle shaft should slide out of the hub bore. If axle is stuck in hub, use a hub puller or slide hammer with appropriate adapters to extract. Be careful not to damage the CV joint boot or allow the axle to hang unsupported - secure with wire if needed.
7. 7

   Remove knuckle from vehicle
   Once all connections are separated and axle is clear, maneuver the knuckle assembly free from the vehicle. This may require rotating and tilting the knuckle to clear the wheel well and suspension components. Remove the knuckle and place on clean work surface for inspection.
8. 8

   Inspect and prepare new knuckle
   Inspect the new knuckle for any shipping damage or defects. Verify all mounting points, tapers, and threaded holes are clean and undamaged. If wheel hub is separate from knuckle, press or bolt hub assembly into new knuckle according to manufacturer specifications. Apply anti-seize to all mating surfaces and threaded fasteners unless otherwise specified.
9. 9

   Install knuckle assembly
   Carefully position the new knuckle assembly into the vehicle, aligning the hub bore with the CV axle shaft. Guide the axle through the hub while simultaneously positioning the knuckle for connection to upper and lower suspension mounting points. Ensure CV axle is fully seated in hub splines.
10. 10

    Connect lower ball joint
    Align the lower ball joint stud with the knuckle taper. Ensure taper is clean and seats properly. Install new pinch bolt or castellated nut. If using castle nut, tighten to specification and install new cotter pin. For pinch bolt design, tighten to proper torque value ensuring bolt threads are properly engaged.
11. 11

    Connect upper control arm or strut
    Align and connect the upper ball joint to knuckle or install strut-to-knuckle bolts. Ensure proper seating of all components. Install new fasteners and tighten to manufacturer specification. If ball joint uses castle nut, align slots with cotter pin hole and install new cotter pin.
12. 12

    Connect tie rod end and install axle nut
    Insert the outer tie rod end stud into the knuckle steering arm. Install new castle nut or lock nut and tighten to specification. Install new cotter pin if applicable. Install new axle nut on CV axle shaft and tighten to proper torque specification while preventing hub rotation. Stake or install lock collar if required by design.
13. 13

    Install ABS sensor and brake components
    Clean the ABS sensor bore in the new knuckle. Apply a light coating of anti-seize or sensor grease to sensor body. Install ABS sensor and secure with mounting bolt to proper torque. Reconnect electrical connector ensuring positive lock engagement. Install brake rotor and secure with mounting screws. Install brake caliper and tighten mounting bolts to specification.
14. 14

    Install wheel and perform initial checks
    Install wheel and hand-tighten lug nuts in star pattern. Lower vehicle until tire just contacts ground to prevent rotation. Torque lug nuts to specification in star pattern. Fully lower vehicle and perform final torque check on all lug nuts.

Reassembly

1. All fasteners must be torqued to Rivian manufacturer specifications - consult service manual for exact values
2. Use only new single-use fasteners such as axle nut, castle nuts, and cotter pins
3. Ensure all electrical connectors are fully seated and locked
4. Verify CV axle is fully engaged in hub and differential
5. Check that brake caliper has proper clearance and moves freely on slides

Verification

• Reconnect 12V battery and clear any diagnostic trouble codes that may have set
• With vehicle on ground, turn steering wheel lock-to-lock to verify full range of motion without binding or interference
• Start vehicle and verify ABS warning light extinguishes after bulb check
• Pump brake pedal several times to ensure firm pedal before moving vehicle
• Test drive vehicle at low speed in safe area to verify proper operation, no unusual noises, and brake function
• Schedule four-wheel alignment immediately after repair - suspension geometry has been altered
• Recheck all fastener torques after 50-100 miles of driving
• Verify no warning lights are illuminated and scan for diagnostic codes

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