This procedure covers the removal and replacement of the front or rear radius arm on a 2023 Rivian EDV 500 commercial van, including suspension disassembly and reassembly.

Warnings

Tools required

Parts

• Radius arm assembly × 1 — Use OEM specification
• Radius arm bushing kit (if rebuilding) × 1 — Use OEM specification
• Cotter pins (various sizes) × 4 — Use OEM specification
• Nylock nuts (if applicable) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 2 minutes for system discharge
3. Loosen wheel lug nuts while vehicle is on ground
4. Raise vehicle using floor jack at manufacturer-specified lift points
5. Support vehicle with heavy-duty jack stands rated for commercial vehicle weight
6. Remove wheel and tire assembly from affected corner
7. Spray all suspension fasteners with penetrating oil and allow to soak for 15 minutes
8. Take photos of assembly for reference during reassembly

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the suspension weight. Raise jack until it just contacts the control arm but does not lift the vehicle. This prevents the suspension from dropping when components are disconnected.
2. 2

   Remove shock absorber lower mounting
   Locate the shock absorber lower mounting bolt connecting to the lower control arm or knuckle assembly. Remove the mounting bolt and nut, then push the shock absorber up and secure it out of the way with a bungee cord or wire to prevent damage.
3. 3

   Disconnect stabilizer bar link
   If the stabilizer bar link interferes with radius arm access, disconnect it from the lower control arm. Hold the ball stud with a wrench to prevent spinning while removing the retaining nut. Remove the link from the control arm.
4. 4

   Mark radius arm position
   Before removal, use a paint pen or scribe to mark the relationship between the radius arm and its mounting brackets at both the frame and axle or control arm ends. These marks will help with initial alignment during installation.
5. 5

   Remove radius arm frame mounting fasteners
   Locate the radius arm mounting bolts at the frame rail. These are typically large diameter bolts with through-bushings. Support the radius arm with one hand or a support stand, then remove the frame mounting bolt(s) and flag washer if equipped. Do not allow the arm to drop suddenly.
6. 6

   Remove radius arm axle/control arm mounting
   Move to the outer end of the radius arm where it connects to the axle housing or lower control arm bracket. Remove the mounting bolt(s) and any spacers or washers. Note the orientation and position of all hardware for proper reassembly.
7. 7

   Remove radius arm from vehicle
   Carefully maneuver the radius arm out of the mounting brackets. It may require rotation or angling to clear surrounding components such as brake lines, wiring harnesses, or the drive motor housing on this electric vehicle. Inspect the removed arm for damage, cracking, or worn bushings.
8. 8

   Inspect mounting points
   With the radius arm removed, thoroughly inspect both mounting points on the frame and axle/control arm for damage, elongated bolt holes, or cracked brackets. Clean all mounting surfaces with a wire brush and inspect bushings in mounting brackets for wear or deterioration.
9. 9

   Prepare new radius arm
   If installing a new radius arm assembly, verify it matches the removed part and includes all necessary bushings and hardware. If rebuilding the existing arm with new bushings, press out old bushings and press in new ones according to manufacturer orientation specifications. Lubricate bushings with appropriate lubricant per OEM specifications.
10. 10

    Install radius arm to axle/control arm
    Position the new or rebuilt radius arm and align it with the axle housing or lower control arm mounting bracket. Insert the mounting bolt with any required spacers or washers in their original orientation. Thread the nut onto the bolt but do not fully tighten yet - leave the joint free to pivot.
11. 11

    Install radius arm to frame
    Align the forward end of the radius arm with the frame mounting bracket, using the alignment marks made during disassembly as a guide. Insert the frame mounting bolt with any flag washers in their correct orientation. Thread the nut onto the bolt but do not fully tighten - suspension fasteners must be torqued at ride height.
12. 12

    Reconnect stabilizer bar link
    If previously disconnected, reconnect the stabilizer bar link to the lower control arm. Install the nut and tighten while holding the ball stud to prevent spinning. Leave slightly loose until final torque sequence.
13. 13

    Reinstall shock absorber
    Release the shock absorber from its secured position and align the lower mounting eye with the mounting bracket. Install the lower shock bolt and nut, threading by hand initially. Do not fully tighten yet.
14. 14

    Load suspension to ride height
    Using the floor jack under the lower control arm, carefully raise the suspension until the vehicle just begins to lift off the jack stands or until the suspension is at normal ride height geometry. This is critical - suspension bushings must be torqued at ride height to prevent premature bushing failure.
15. 15

    Torque all fasteners
    With suspension at ride height, torque all radius arm mounting bolts, shock absorber mounting bolts, and stabilizer link fasteners to manufacturer specifications. Since specific torque values are not available in the database, consult the Rivian service manual for proper torque specifications. Install new cotter pins where applicable.

Reassembly

1. Lower the floor jack from under the control arm slowly
2. Reinstall wheel and tire assembly, torquing lug nuts to manufacturer specification in a star pattern
3. Lower vehicle to ground and perform final lug nut torque check
4. Reconnect 12V battery negative terminal
5. Test drive vehicle at low speed in a safe area to verify proper operation and listen for unusual noises
6. Schedule immediate wheel alignment service - radius arm replacement directly affects suspension geometry and alignment

Verification

• Visually inspect all radius arm mounting bolts to confirm they are properly torqued and hardware is secure
• Check for adequate clearance between radius arm and surrounding components through full suspension travel
• Perform a test drive and verify no unusual noises, vibrations, or handling issues
• Verify vehicle tracks straight during initial low-speed test
• Have wheel alignment performed and checked by qualified technician - verify camber, caster, and toe are within specification
• Re-inspect all fasteners after 50-100 miles of driving

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