This procedure covers the removal and replacement of the rear leaf spring shackle on the 2023 Rivian EDV 500 commercial delivery van, including disassembly of mounting hardware and proper alignment during installation.

Warnings

Tools required

Parts

• Leaf spring shackle assembly × 1 — Use OEM specification
• Shackle bushings × 2 — Use OEM specification
• Shackle mounting bolts × 2 — Use OEM specification
• Lock nuts × 2 — Use OEM specification
• Anti-seize compound × 1 — High-temperature rated

Preparation

1. Park vehicle on level, solid surface and apply parking brake
2. Place wheel chocks in front of front wheels
3. Open hood and disconnect 12V battery negative terminal
4. Spray all shackle mounting hardware with penetrating oil and allow to soak for at least 30 minutes
5. Loosen rear wheel lug nuts while vehicle is on ground
6. Raise rear of vehicle with floor jack at manufacturer-specified jacking point
7. Install jack stands under frame rails on both sides for stability
8. Remove rear wheel on side being serviced
9. Verify vehicle is stable and cannot roll or shift

Procedure

1. 1

   Inspect and document current shackle condition
   Photograph the existing shackle assembly orientation and mounting position. Note the position of any washers, spacers, or alignment shims. Check for frame damage around mounting points that may indicate underlying issues. Measure the distance from the shackle mounting bolt centerline to a fixed reference point on the frame for reinstallation alignment.
2. 2

   Support the leaf spring assembly
   Place a floor jack with a wood block under the axle tube or spring seat near the shackle end of the leaf spring. Raise the jack just enough to slightly compress the spring and relieve tension on the shackle bolts, but do not lift the axle. This prevents the spring from dropping suddenly when hardware is removed.
3. 3

   Remove lower shackle bolt
   Using a 21mm or 24mm socket (verify actual size on your vehicle), remove the nut from the lower shackle bolt that connects the shackle to the leaf spring eye. Hold the bolt head with another wrench if it spins. Once nut is removed, tap the bolt out using a rubber mallet. If bolt is seized, apply heat carefully away from rubber bushings and use a brass drift punch to drive it out. Do not remove upper bolt yet.
4. 4

   Remove upper shackle mounting bolts
   Locate the two bolts securing the upper portion of the shackle to the frame bracket. These are typically 19mm or 21mm bolts. Remove both nuts while supporting the shackle with one hand. Once fasteners are loose, remove the bolts and carefully lower the shackle assembly. The spring may shift slightly when freed; maintain jack support.
5. 5

   Remove old shackle and inspect mounting points
   With all hardware removed, separate the shackle from the leaf spring eye. Inspect the spring eye for cracks, elongation, or excessive wear. Clean the frame mounting bracket with a wire brush, removing all rust, old thread locker, and debris. Inspect frame bracket for cracks or distortion. Check frame mounting bolt holes for elongation or thread damage.
6. 6

   Prepare new shackle assembly
   Unbox the new shackle and verify it matches the old unit in length and bushing configuration. Install new bushings into the shackle eyes if not pre-installed, ensuring they are fully seated and oriented correctly. Apply a thin coat of anti-seize compound to the inner sleeve of each bushing to prevent corrosion and facilitate future removal.
7. 7

   Install shackle to frame bracket
   Position the new shackle into the frame bracket, aligning the mounting holes. Insert both frame mounting bolts through the bracket and shackle. Start both lock nuts by hand, ensuring threads engage properly. Do not fully tighten yet. Verify the shackle hangs perpendicular to the frame and can pivot freely.
8. 8

   Connect shackle to leaf spring
   Use the floor jack to carefully raise or lower the spring eye to align with the lower shackle hole. This may require adjusting jack height several times. Once aligned, insert the lower shackle bolt through the spring eye and shackle. Apply anti-seize to bolt threads and start the lock nut by hand. Do not fully tighten yet.
9. 9

   Adjust suspension to ride height before final torque
   With all hardware installed finger-tight, raise the floor jack under the axle until the suspension is at normal ride height (vehicle weight on suspension, no additional compression or extension). This ensures bushings are torqued in their operating position, preventing premature wear. The vehicle should be at the same height as when resting on the ground.
10. 10

    Torque all shackle hardware to specification
    While maintaining ride height with the floor jack, torque all shackle mounting hardware. Since specific torque values are not available in the database, consult the Rivian service manual for exact specifications (typically 100-150 ft-lbs for shackle bolts on commercial vehicles of this class). Torque the upper frame mounting bolts first, then the lower spring-to-shackle bolt. Follow proper torque sequence if specified by manufacturer.
11. 11

    Verify shackle movement and clearances
    Remove the floor jack from under the spring and allow the suspension to cycle through its full range of motion by pushing down on the vehicle body. Verify the shackle pivots freely without binding and has adequate clearance to all surrounding components including the frame, body panels, and brake lines. Check that no wiring or hoses contact the shackle.

Reassembly

1. Reinstall the rear wheel and torque lug nuts to manufacturer specification (typically 150 ft-lbs for commercial vehicles)
2. Raise vehicle slightly and remove jack stands
3. Lower vehicle completely to ground
4. Reconnect 12V battery negative terminal
5. Remove wheel chocks
6. Bounce the rear of the vehicle several times to settle the suspension into its operating position

Verification

• Test drive the vehicle at low speed in a safe area and listen for any unusual noises from the rear suspension
• Perform figure-eight maneuvers to load the suspension and verify proper shackle operation
• After 50-100 miles of operation, re-torque all shackle hardware to ensure fasteners have not loosened
• Inspect for any fluid leaks around the work area, particularly from nearby brake components
• Verify rear axle alignment has not changed by checking tire wear patterns over the next 500 miles; consider professional alignment check if vehicle pulls or tires show uneven wear

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