This procedure covers the removal and replacement of the front lower control arm on a 2023 Rivian EDV 500 delivery van with dual motor AWD drivetrain.

Warnings

Tools required

Parts

• Front lower control arm × 1 — Use OEM specification
• Control arm to frame bolts × 2 — Use OEM specification
• Ball joint castle nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal and wait 2 minutes for system discharge
4. Loosen front wheel lug nuts while vehicle is on ground
5. Raise front of vehicle using appropriate lift points per Rivian service manual
6. Support vehicle on jack stands rated for EV weight (minimum 3 tons per stand)
7. Remove front wheel on affected side
8. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the weight of the suspension assembly. Raise jack just enough to take up slack but not lift the vehicle.
2. 2

   Remove the ball joint cotter pin and castle nut
   Locate the ball joint connection at the steering knuckle. Remove the cotter pin from the castle nut using pliers or wire cutters. Remove the castle nut using appropriate socket. Keep the nut for comparison with replacement hardware.
3. 3

   Separate the ball joint from the knuckle
   Install ball joint separator tool between the control arm and steering knuckle. Strike the tool with a hammer or apply pressure per tool design to separate the ball joint taper from the knuckle. Do not damage the CV boot or brake components during separation.
4. 4

   Disconnect sway bar end link (if equipped)
   If the sway bar end link connects to the lower control arm on this side, remove the mounting bolt or nut securing the end link to the control arm. Support the end link to prevent damage to the sway bar bushings.
5. 5

   Remove front control arm mounting bolt
   Locate the forward control arm mounting bolt that secures the control arm to the front subframe. Use a breaker bar to loosen and remove this bolt completely. Note the orientation of any washers or spacers for reinstallation.
6. 6

   Remove rear control arm mounting bolt
   Locate the rear control arm mounting bolt that secures the control arm to the subframe or chassis. This bolt may pass through a bushing assembly. Remove the bolt completely while supporting the control arm with the floor jack.
7. 7

   Remove the lower control arm
   Carefully lower the floor jack to relieve tension on the control arm. Maneuver the control arm out of the mounting points and away from the vehicle. Note the position of any shims, spacers, or alignment hardware for reinstallation.
8. 8

   Clean mounting surfaces
   Use a wire brush to clean the mounting bolt holes in the subframe and the ball joint taper seat in the steering knuckle. Remove any rust, dirt, or debris that could affect installation or alignment. Inspect mounting areas for damage or excessive wear.
9. 9

   Install the new lower control arm
   Position the new lower control arm into the mounting points on the subframe. Align the bolt holes and insert the rear mounting bolt first, threading it by hand. Install the front mounting bolt but do not fully tighten either bolt at this time.
10. 10

    Connect the ball joint to the knuckle
    Raise the floor jack to lift the control arm and align the ball joint stud with the hole in the steering knuckle. Insert the ball joint stud fully into the knuckle taper. Install the new castle nut and tighten until the ball joint taper is fully seated.
11. 11

    Install castle nut and cotter pin
    Tighten the ball joint castle nut to proper specification (consult Rivian service documentation). Continue tightening to align the next castle slot with the cotter pin hole if necessary. Install a new cotter pin and bend the ends to secure.
12. 12

    Reconnect sway bar end link (if equipped)
    If the sway bar end link was disconnected, reconnect it to the lower control arm. Install the mounting bolt or nut and tighten to specification.
13. 13

    Torque control arm mounting bolts
    With the vehicle weight on the suspension (jack supporting but not lifting), torque both control arm mounting bolts to manufacturer specification. Bolts must be torqued with suspension at ride height to prevent bushing binding. Consult Rivian service documentation for exact torque values.

Reassembly

1. Reinstall the wheel and hand-tighten lug nuts in a star pattern
2. Lower vehicle to the ground and remove jack stands
3. Torque wheel lug nuts to manufacturer specification in a star pattern
4. Reconnect 12V battery negative terminal
5. Rock vehicle side to side to settle suspension components

Verification

• Perform a visual inspection to ensure all fasteners are installed and properly torqued
• Verify the ball joint cotter pin is properly installed and secured
• Check for proper clearance between control arm and surrounding components through full suspension travel
• Test drive vehicle at low speed in a safe area and listen for any unusual noises from the front suspension
• Have vehicle alignment checked and adjusted by a qualified technician with Rivian-specific alignment specifications
• Verify proper steering response and that vehicle tracks straight

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