This procedure covers the removal and replacement of the rear lower control arm on a 2023 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Rear lower control arm × 1 — Use OEM specification
• Control arm mounting bolts × 1 — Use OEM specification
• Ball joint 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 in front of front wheels
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Raise rear of vehicle with floor jack at designated rear lift points
5. Support vehicle on jack stands at manufacturer-specified support points
6. Remove rear wheel on affected side
7. Spray all control arm fasteners with penetrating lubricant and allow to soak for 10-15 minutes

Procedure

1. 1

   Support rear suspension
   Position a floor jack under the rear knuckle or lower suspension component on the side being serviced. Raise jack just enough to contact and slightly compress the suspension, relieving tension from the control arm. This prevents the suspension from dropping when fasteners are removed.
2. 2

   Disconnect ball joint from knuckle
   Locate the lower control arm ball joint connection at the rear knuckle. Remove the castle nut or retaining nut securing the ball joint to the knuckle. Remove and discard the cotter pin if equipped. Use a ball joint separator tool to press the ball joint taper out of the knuckle bore. Do not hammer directly on threads.
3. 3

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the front bushing bracket on the subframe. Use a socket and breaker bar to remove the bolt. Note the orientation of any washers or spacers for reinstallation. Support the control arm with one hand as you remove the bolt.
4. 4

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the rear bushing bracket on the subframe. Remove the bolt completely using appropriate sockets. The control arm may now be loose but could still be held by alignment with bushings.
5. 5

   Remove lower control arm
   Carefully maneuver the lower control arm out of the mounting brackets. You may need to use a pry bar to separate bushings from brackets. Inspect the removed control arm for damage, torn bushings, or reasons for replacement. Check mounting areas on subframe for damage or excessive rust.
6. 6

   Clean mounting surfaces
   Use a wire brush to clean all mounting surfaces on the subframe brackets where the control arm bushings mate. Remove any rust, debris, or old thread locker from bolt holes. Inspect ball joint taper bore in knuckle and clean if necessary.
7. 7

   Install new lower control arm
   Position the new lower control arm into the mounting brackets. Align the front bushing with the front bracket first, then insert the front mounting bolt hand-tight. Align the rear bushing and insert the rear mounting bolt hand-tight. Do not fully tighten mounting bolts yet.
8. 8

   Connect ball joint to knuckle
   Raise or lower the floor jack supporting the suspension to align the control arm ball joint with the knuckle bore. Insert the ball joint stud into the knuckle taper. Install the new castle nut or retaining nut and tighten until the ball joint taper seats firmly. Install a new cotter pin if equipped and bend ends to secure.
9. 9

   Load suspension to ride height
   With all fasteners hand-tight, adjust the floor jack under the knuckle to simulate normal ride height. The suspension should be at approximately the same position as when the vehicle is resting on its wheels. This ensures bushings are tightened at the correct orientation to prevent premature wear.
10. 10

    Torque control arm mounting bolts
    With suspension loaded to ride height, apply medium-strength thread locker to mounting bolt threads. Torque the front and rear control arm mounting bolts to manufacturer specifications. Since specific torque values are not available in the database, refer to the Rivian service manual or torque specifications typically range from 100-150 ft-lbs for control arm mounting bolts on vehicles of this class.
11. 11

    Remove jack and reinstall wheel
    Carefully lower and remove the floor jack from under the suspension. Reinstall the rear wheel and hand-tighten lug nuts in a star pattern. Lower the vehicle from jack stands to the ground.
12. 12

    Final torque wheel lug nuts
    With vehicle on the ground, torque wheel lug nuts to specification in a star pattern. Typical specification for Rivian EDV 500 is approximately 150 ft-lbs, but verify with manufacturer documentation.

Reassembly

1. Ensure all mounting bolts were torqued with suspension at ride height to prevent bushing bind
2. Verify ball joint is properly seated and secured with cotter pin
3. Double-check that no tools or parts were left in the wheel well area

Verification

• Test drive vehicle at low speed in a safe area and listen for unusual noises from rear suspension
• Check for proper handling and absence of pulling or wandering
• Schedule immediate wheel alignment service - alignment is mandatory after control arm replacement
• After alignment, verify tire wear patterns over next 500 miles to ensure proper geometry
• Re-torque all suspension fasteners after 50-100 miles of driving

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