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

Warnings

Tools required

Parts

• Lower control arm assembly × 1 — Use OEM specification
• Control arm to frame mounting bolts × 2 — Typically replaced during service
• Ball joint castle nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on a level, solid surface and engage parking brake
2. Place wheel chocks behind the rear wheels
3. Disconnect the 12V battery negative terminal and wait 2 minutes
4. Loosen the wheel lug nuts on the affected side while vehicle is still on the ground
5. Raise the front of the vehicle with a floor jack at the designated jacking point
6. Secure the vehicle on jack stands at the frame rails, not on suspension components
7. Remove the wheel and tire assembly completely
8. Spray all control arm fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Support the knuckle assembly
   Position a floor jack under the steering knuckle or lower control arm to support the weight of the suspension assembly. Raise the jack just enough to take the load off the control arm but do not lift the vehicle. This prevents the suspension from dropping suddenly when fasteners are removed.
2. 2

   Remove the ball joint castle nut
   Remove the cotter pin from the ball joint castle nut using pliers or a cotter pin removal tool. Discard the cotter pin as it should not be reused. Using the appropriate socket, loosen and remove the castle nut from the ball joint stud. Keep the nut for reference when installing the new control arm.
3. 3

   Separate the ball joint from the knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the lower ball joint from the steering knuckle. Position the tool between the control arm and knuckle, then strike or actuate the tool to break the taper fit. If using a pickle fork, be aware this may damage the ball joint boot. Alternatively, use a ball joint press tool for cleaner separation. Do not strike the ball joint stud directly with a hammer.
4. 4

   Disconnect any electrical connections or sensors
   Inspect the control arm area for any wheel speed sensors, ride height sensors, or electrical connectors that may be attached to or routed near the control arm. On the Rivian EDV 500, there may be suspension position sensors. Disconnect any electrical connectors by pressing the release tab and carefully pulling apart. Note the routing of any wiring for reinstallation.
5. 5

   Remove the rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the subframe or chassis. This is typically the bolt toward the rear of the vehicle. Using a breaker bar and appropriate socket, remove the bolt completely. Support the control arm with your hand as you remove the bolt. The bolt may have a captured washer or bushing that should be noted for reinstallation.
6. 6

   Remove the front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the subframe or chassis. This bolt is typically larger and may require holding a nut on the opposite side. Using a breaker bar, socket, and wrench if needed, remove the front mounting bolt completely. The control arm should now be free from the vehicle.
7. 7

   Remove the lower control arm
   With all fasteners removed and the ball joint separated, carefully maneuver the lower control arm out of the vehicle. You may need to angle it or compress the suspension slightly using the support jack. Inspect the mounting points on the subframe for damage, corrosion, or worn bushings in the frame. Clean the mounting surfaces with a wire brush if necessary.
8. 8

   Prepare the new control arm
   Unpack the new lower control arm and compare it to the old part to verify correct fitment. Check that all bushings are properly seated and that the ball joint moves freely but without excessive play. If the control arm came with protective caps or covers on the ball joint, remove them before installation.
9. 9

   Install the new control arm into position
   Maneuver the new control arm into position, aligning the mounting points with the subframe holes. You may need to use a pry bar or adjust the support jack height to align the holes properly. Insert the front mounting bolt first, threading it by hand to hold the control arm in place. Do not fully tighten yet.
10. 10

    Install the rear mounting bolt
    Align the rear bushing with its mounting point and insert the rear mounting bolt. Thread it by hand to ensure proper engagement. With both mounting bolts installed finger-tight, check that the control arm moves freely and is not binding. Adjust the support jack height if needed to achieve proper alignment.
11. 11

    Connect the ball joint to the knuckle
    Raise or lower the support jack under the knuckle to align the ball joint stud with the hole in the steering knuckle. The taper on the ball joint stud must seat fully into the knuckle. Install the castle nut onto the ball joint stud and thread it down by hand. Use a socket and torque wrench to tighten the castle nut to specification. The slots in the castle nut must align with the hole in the stud for the cotter pin.
12. 12

    Install new cotter pin
    Insert a new cotter pin through the hole in the ball joint stud and through the castle nut slots. Bend the ends of the cotter pin outward to secure it in place. The cotter pin should not be able to fall out with the ends properly bent. Never reuse old cotter pins.
13. 13

    Torque the control arm mounting bolts
    With the vehicle weight now on the suspension (supported by jack stands), torque the front and rear control arm mounting bolts to manufacturer specification. It is critical that these bolts are torqued with the suspension at normal ride height or the bushings may bind. Use a calibrated torque wrench and tighten in the sequence specified by the manufacturer. Note: Specific torque values are not available in the database and must be obtained from Rivian service documentation.
14. 14

    Reconnect electrical connections
    Reconnect any wheel speed sensors, suspension position sensors, or other electrical connections that were disconnected earlier. Ensure the connectors click securely into place and that wiring is routed properly away from moving suspension components and heat sources. Verify that no wires are pinched or stretched.
15. 15

    Reinstall wheel and lower vehicle
    Reinstall the wheel and tire assembly, threading the lug nuts by hand to start. Lower the vehicle carefully from the jack stands until the tire just touches the ground but the vehicle weight is still supported. Torque the lug nuts to specification in a star pattern. Fully lower the vehicle and remove the jack. Remove wheel chocks and reconnect the 12V battery.

Reassembly

1. Ensure all fasteners are tightened to the correct torque specifications before operating the vehicle
2. Double-check that the cotter pin is properly installed and bent to prevent loss
3. Verify all electrical connections are secure and properly routed
4. Control arm mounting bolts must be torqued at normal ride height to prevent bushing binding

Verification

• Perform a visual inspection of all installed components to ensure proper fitment and torque
• Bounce the front suspension several times to settle the components and verify no unusual noises
• Test drive the vehicle at low speed in a safe area to verify proper operation and handling
• Check for any warning lights on the instrument cluster related to suspension or wheel speed sensors
• Schedule a professional wheel alignment as soon as possible, as control arm replacement will affect alignment settings
• After 50-100 miles of driving, re-inspect all fasteners to ensure they remain tight

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