suspension

Knuckle/Spindle - Rear

for 2023 Rivian EDV 500 Dual Motor AWD (EDV) · AWD

Editorial review:Chris Hackleman — Master Technician · 20+ years · Jeff Moore — Master Lexus & Toyota Mechanic · 20+ years

Difficulty

Advanced

Time

3.0 h

Tools

Steps

✓Expert-verified. Personally reviewed and approved by OLP's master technicians (Chris Hackleman & Jeff Moore — 20+ years each). Always follow the vehicle's factory service information and torque specs.

This procedure covers the removal and replacement of the rear wheel knuckle/spindle assembly on a 2023 Rivian EDV 500 electric delivery van.

Warnings

⚠️Vehicle battery must be disconnected and high-voltage system disabled per manufacturer protocol before beginning work. Failure to do so may result in electric shock or system damage.

⚠️Never work under a vehicle supported only by a jack. Always use properly rated jack stands.

⚠The rear motor assembly generates significant heat during operation. Allow vehicle to cool for at least 2 hours before beginning work.

⚠Suspension components are under tension. Use caution when separating ball joints and control arms.

ℹ️This vehicle uses an independent rear suspension with integrated motor drive units. Extra care must be taken around motor housing and CV axle assemblies.

Tools required

Floor jack and jack stands rated for vehicle weightEssential

Torque wrench (50-250 ft-lb range)Essential

Socket set (metric)Essential

Breaker barEssential

Pry barEssential

Ball joint separator/pickle forkEssential

Hub puller tool

Brake caliper hanger/wireEssential

Impact wrench

Penetrating oil

Wheel chocksEssential

Brass punch and hammer

Dial indicator for bearing preload check

Parts

Rear wheel knuckle/spindle assembly × 1 — Use OEM specification
Wheel hub assembly (if integrated) × 1 — Use OEM specification
Lower control arm ball joint castle nut × 1 — Use OEM specification
Upper control arm ball joint castle nut × 1 — Use OEM specification
Tie rod end castle nut × 1 — Use OEM specification
Axle hub nut × 1 — Use OEM specification
Brake caliper mounting bolts × 2 — Use OEM specification
Cotter pins (various sizes) × 3 — Use OEM specification

Fluids

DOT 4 Brake Fluid — 0.5 qt

Preparation

Place vehicle on level surface and apply parking brake firmly
Place wheel chocks in front of front wheels
Disable high-voltage system following Rivian service manual lockout/tagout procedure
Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
Loosen rear wheel lug nuts while vehicle is on ground
Raise rear of vehicle and support securely on jack stands at manufacturer-specified lift points
Remove rear wheel and tire assembly
Inspect work area for any high-voltage cables (typically orange) and ensure they are clear of work area

Procedure

1
Remove brake caliper assembly
Remove the two brake caliper mounting bolts. Carefully lift caliper off the rotor without twisting or straining the brake hose. Support the caliper using a wire or caliper hanger - do not allow it to hang by the brake hose. Do not press the brake pedal with caliper removed.
2
Remove brake rotor
If present, remove any rotor retaining screws or clips. Slide the brake rotor off the hub. If rotor is stuck, apply penetrating oil and use a brass punch to tap around the hat section to break it loose. On EDV models, the rotor may have locating pins that must be cleared.
3
Remove rear axle hub nut
Remove the cotter pin from the axle hub nut if equipped. Use a breaker bar and appropriate socket to remove the large axle hub nut while having an assistant apply the parking brake, or use a pry bar through the wheel studs to prevent rotation. This nut is typically very tight and may require significant force. Keep the nut if reusing per specifications.
4
Disconnect ABS wheel speed sensor
Locate the ABS wheel speed sensor connector near the knuckle or on the chassis. Disconnect the electrical connector and carefully remove any routing clips. Note the exact routing path for reinstallation. Remove the sensor mounting bolt and carefully extract the sensor from the knuckle to prevent damage to the sensor tip.
5
Disconnect tie rod end
Remove the cotter pin from the tie rod end castle nut. Loosen but do not fully remove the castle nut. Use a ball joint separator or pickle fork to separate the tie rod end from the knuckle. Once separated, remove the nut completely and pivot the tie rod out of the way. Count and record the number of visible threads on the tie rod for alignment reference.
6
Disconnect lower control arm ball joint
Remove the cotter pin from the lower control arm ball joint castle nut. Loosen the nut several turns but leave it threaded on. Use a ball joint separator tool to break the taper joint free from the knuckle. This may require significant force. Once the joint releases, remove the castle nut completely and lower the control arm away from the knuckle.
7
Disconnect upper control arm ball joint
Remove the cotter pin from the upper control arm ball joint castle nut. Loosen the nut several turns but leave it threaded on to prevent the knuckle from falling. Use a ball joint separator to break the taper joint free. Once separated, support the knuckle assembly and remove the castle nut completely.
8
Remove knuckle and hub assembly from axle
With all connections freed, carefully pull the knuckle assembly outward away from the vehicle to disengage it from the CV axle shaft. The hub may be tight on the splines. Use a hub puller if necessary or tap the end of the axle with a brass punch while pulling outward on the knuckle. Be careful not to damage the CV axle shaft or boots. Once clear, remove the knuckle assembly completely.
9
Inspect components and prepare new knuckle
Inspect the CV axle splines, boots, and shaft for damage. Check all ball joint boots on control arms for tears or damage. Clean the axle shaft splines with a wire brush. If the hub bearing is integrated with the knuckle, ensure the new assembly includes the bearing. If separate, transfer the hub bearing to the new knuckle per manufacturer procedure. Clean all mounting surfaces on the new knuckle.
10
Install knuckle onto CV axle
Align the new knuckle hub with the CV axle splines. Push the knuckle straight onto the axle shaft, ensuring proper spline engagement. The hub should slide on smoothly - do not force it. If resistance is encountered, verify spline alignment. Push the knuckle fully onto the axle until it seats properly.
11
Connect upper control arm ball joint
Position the knuckle so the upper control arm ball joint stud aligns with the knuckle bore. Insert the ball joint stud into the knuckle and install a new castle nut. Tighten the nut to manufacturer specification (torque value not available - reference service manual). Install a new cotter pin through the castle nut slots and bend the ends to secure.
12
Connect lower control arm ball joint
Align the lower control arm ball joint stud with the knuckle bore. Insert the stud and install a new castle nut. Tighten the nut to manufacturer specification (torque value not available - reference service manual). Install a new cotter pin and secure properly. Verify the ball joint has no excessive play.
13
Connect tie rod end
Insert the tie rod end ball stud into the knuckle steering arm. Install a new castle nut and tighten to manufacturer specification (torque value not available - reference service manual). Verify the tie rod thread position matches your reference measurement from disassembly. Install a new cotter pin and bend to secure.
14
Install axle hub nut
Install a new axle hub nut onto the CV axle shaft. Tighten the nut to manufacturer specification while preventing hub rotation using the same method as removal. The nut must be torqued properly to ensure correct hub bearing preload. Install a new cotter pin if equipped, or stake the nut per manufacturer requirements.
15
Reinstall ABS sensor and brake components
Clean the ABS sensor mounting bore in the knuckle. Apply a thin coat of anti-seize to the sensor body (not the tip). Install the sensor and tighten the mounting bolt securely. Reconnect the electrical connector and secure all routing clips. Install the brake rotor, ensuring it seats flush on the hub. Install the brake caliper over the rotor with new mounting bolts if required and tighten to specification. Pump the brake pedal several times to reseat the caliper pistons before moving the vehicle.

Reassembly

Install wheel and tire assembly, starting lug nuts by hand to prevent cross-threading
Lower vehicle until tire just touches ground to prevent hub rotation
Torque wheel lug nuts to manufacturer specification in a star pattern
Lower vehicle completely and remove jack stands
Reconnect 12V battery negative terminal
Re-enable high-voltage system per manufacturer procedure
Check brake fluid level and top off with DOT 4 brake fluid if necessary

Verification

Start vehicle and verify no warning lights related to ABS, traction control, or brake system are illuminated
Test drive vehicle in a safe area at low speed and verify no unusual noises from the rear suspension
Apply brakes firmly to verify proper brake operation and pedal feel
Verify steering returns to center and there is no binding or unusual effort required
Have vehicle alignment checked and adjusted by a qualified technician as soon as possible - suspension geometry has been altered and alignment is critical for safe operation
Recheck all fastener torques after 50-100 miles of driving
Monitor for any unusual tire wear patterns which may indicate alignment issues

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