This procedure covers the removal and replacement of the rear leaf spring assembly on the 2023 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Leaf spring assembly × 1 — Use OEM specification
• Leaf spring shackle bushings × 4 — Use OEM specification
• Leaf spring center bolt × 1 — Use OEM specification
• U-bolt kit (with nuts and washers) × 1 — Use OEM specification
• Front eye bushing × 1 — Use OEM specification
• Rear shackle × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and apply parking brake
2. Chock the front wheels securely
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Disconnect 12V battery negative terminal and wait 2 minutes
5. Lift rear of vehicle using floor jack at designated rear lift point
6. Place jack stands under frame rails at designated support points
7. Remove rear wheel on the side being serviced
8. Spray all leaf spring mounting hardware with penetrating lubricant and allow to soak

Procedure

1. 1

   Support rear axle
   Position a floor jack under the rear axle housing on the side being serviced, directly beneath the differential. Raise jack until it just contacts the axle to support its weight but does not lift the vehicle further. This prevents the axle from dropping when the leaf spring is removed.
2. 2

   Remove shock absorber lower mounting
   Locate the rear shock absorber lower mounting bolt at the axle bracket. Using appropriate socket, remove the lower shock mounting bolt and washer. Allow shock absorber to hang freely or secure it with wire to prevent strain on upper mount.
3. 3

   Remove U-bolts
   Locate the two U-bolts that secure the leaf spring to the axle housing. Remove all four U-bolt nuts using a socket and breaker bar. Remove the U-bolts, bottom plate, and any spacer blocks. Note the orientation and position of all components for reinstallation.
4. 4

   Remove rear shackle
   Locate the rear leaf spring shackle where the spring connects to the frame bracket. Remove the upper and lower shackle bolts using appropriate wrenches. The spring will now be supported only by the front eye mounting. Carefully lower the jack slightly if needed to access the shackle.
5. 5

   Remove front eye bolt
   Locate the front eye bolt that secures the front of the leaf spring to the frame hanger bracket. Remove the nut and bolt using appropriate wrenches. Support the leaf spring assembly as the bolt is removed to prevent it from falling.
6. 6

   Remove leaf spring assembly
   Carefully lower and maneuver the leaf spring assembly out from under the vehicle. Take note of any alignment shims or spacers at the mounting points. Inspect the frame mounting brackets and axle pad for damage or wear.
7. 7

   Inspect and prepare mounting locations
   Clean all mounting surfaces on the frame hangers and axle housing using a wire brush. Inspect frame brackets for cracks or damage. Check the axle spring pad for corrosion or damage. Replace any damaged components before installing new spring.
8. 8

   Install new front eye bushing
   If not pre-installed in the new leaf spring, install the new front eye bushing into the front eye of the leaf spring. Ensure the bushing is fully seated and properly oriented according to manufacturer specifications.
9. 9

   Position new leaf spring
   Position the new leaf spring assembly under the vehicle, aligning the front eye with the front frame hanger bracket. Install the front eye bolt through the hanger and bushing, but do not fully tighten yet. Thread the nut onto the bolt hand-tight.
10. 10

    Install rear shackle
    Raise the rear of the leaf spring into position using the floor jack under the axle. Install the new rear shackle between the spring eye and frame bracket. Insert and hand-tighten both upper and lower shackle bolts with nuts.
11. 11

    Align spring to axle
    Adjust the floor jack to position the axle so the leaf spring center bolt aligns with the locating hole in the axle spring pad. Ensure the spring is centered on the axle housing with equal overhang on both sides. Install any original spacer blocks or plates.
12. 12

    Install U-bolts
    Position the bottom plate over the spring and against the axle housing. Install both U-bolts through the bottom plate and spring, threading nuts onto all four ends. Tighten nuts in a cross pattern gradually to ensure even clamping. Follow torque specifications if available, otherwise tighten to specification in the Rivian service manual.
13. 13

    Reconnect shock absorber
    Reconnect the rear shock absorber lower mounting bolt through the axle bracket. Install washer and nut. Torque to specification per Rivian service manual.
14. 14

    Torque all fasteners
    With vehicle weight now on the suspension (lower vehicle slightly if needed to load suspension to ride height), torque all leaf spring mounting bolts in the following order: front eye bolt, rear shackle bolts (upper then lower), and U-bolt nuts in cross pattern. Refer to Rivian service manual for specific torque values as none are available in this database.
15. 15

    Reinstall wheel
    Reinstall the rear wheel and hand-tighten lug nuts in star pattern. Remove jack stands and lower vehicle completely to ground. Torque wheel lug nuts to specification in star pattern per Rivian specifications.

Reassembly

1. Reconnect 12V battery negative terminal
2. Verify all fasteners are properly torqued to manufacturer specifications
3. Inspect for proper ground clearance and spring alignment
4. If both sides were serviced, verify equal ride height on both sides

Verification

• Perform a visual inspection to ensure all components are properly installed and secured
• Check that the leaf spring is centered on the axle housing
• Verify no interference between the spring and frame, brake lines, or high-voltage cables
• Test drive vehicle at low speed in a safe area and listen for unusual noises
• Check for proper handling and absence of unusual vibrations
• Re-torque all fasteners after 50-100 miles of driving
• Have alignment checked at qualified service center if vehicle pulls or tracks improperly

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