Strut Assembly - Rear

This procedure covers the removal and replacement of the rear strut assembly on a 2023 Rivian EDV 500, including disconnection of suspension components and proper handling of compressed spring assemblies.

Warnings

Tools required

Parts

• Rear strut assembly (complete with spring) × 1 — Use OEM Rivian specification
• Upper strut mount hardware kit × 1 — Use OEM specification
• Lower strut mounting bolts × 1 — Use OEM specification if reuse not permitted

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks in front of and behind front wheels
3. Open rear cargo area and remove interior trim panels to access upper strut tower mounting points
4. Disconnect 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
5. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
6. Raise rear of vehicle using floor jack at designated lift points and support securely on jack stands rated for vehicle weight
7. Remove rear wheel completely
8. Spray penetrating oil on all strut mounting bolts and allow to soak for 10-15 minutes
9. Support rear knuckle assembly with a floor jack positioned under the lower control arm to prevent dropping when strut is disconnected

Procedure

1. 1

   Access upper strut mounting area
   From inside the vehicle cargo area, locate the upper strut tower cover. Remove any trim panels or covers secured by plastic clips or screws to expose the upper strut mounting nuts. Identify the center strut shaft nut and the surrounding strut tower mounting nuts (typically 3 or 4 nuts around perimeter).
2. 2

   Disconnect brake line and wheel speed sensor
   Locate the brake line bracket attached to the strut body. Remove the bracket bolt to free the brake line from the strut (do not disconnect the brake line itself). Disconnect the wheel speed sensor electrical connector and remove any clips securing the sensor cable to the strut. Route cables clear of the work area.
   ⚠Do not allow brake line to hang unsupported or become kinked. Support with wire or tie if necessary.
3. 3

   Disconnect lower strut mounting bolts
   Locate the two bolts connecting the lower strut body to the rear knuckle assembly. These are typically large diameter bolts passing horizontally through the knuckle. Using a breaker bar and socket, remove both bolts while ensuring the floor jack is supporting the knuckle to prevent sudden movement. Keep bolts for inspection and possible reuse.
4. 4

   Disconnect stabilizer bar link
   If the stabilizer bar end link is connected to the strut assembly, disconnect it now by removing the upper link nut. Hold the ball stud with an Allen key while turning the nut to prevent spinning. Allow the link to hang from the stabilizer bar.
5. 5

   Remove upper strut tower mounting nuts
   From inside the vehicle, carefully remove the upper strut tower mounting nuts (do NOT remove the center shaft nut yet). Typically there are 3-4 nuts around the perimeter of the strut tower. Support the strut assembly from below with the floor jack during this step to prevent it from falling.
   ⚠️The strut assembly is heavy and will drop when the upper nuts are removed. Ensure the floor jack is positioned to support the assembly or have an assistant hold it.
6. 6

   Lower and remove strut assembly
   With all mounting points disconnected and the strut supported on the jack, carefully lower the jack while guiding the strut assembly out of the wheel well. Angle the top of the strut inward and down to clear the body. Remove the complete strut assembly from the vehicle and place on a stable work surface.
7. 7

   Transfer components to new strut (if necessary)
   If replacing a complete strut assembly with spring pre-installed, skip to step 9. If transferring the spring and upper mount from the old strut to a new strut cartridge, install the spring compressor tool on the spring coils according to manufacturer instructions. Compress the spring evenly by alternating between compressor sides until tension is relieved from the upper mount. Remove the center shaft nut while holding the strut shaft with an Allen key. Carefully remove upper mount, bearing plate, spring seat, and spring. Inspect all components for wear or damage.
   ⚠️Spring compressor must be properly installed and engaged on spring coils. Uneven compression or tool failure can cause violent spring release resulting in serious injury or death.
8. 8

   Assemble new strut
   If transferring components, install the compressed spring onto the new strut body, ensuring the spring end seats properly in the lower spring seat groove. Install the upper spring seat, bearing plate, and upper mount in correct orientation (note alignment marks or positioning tabs). Thread on the upper shaft nut and tighten while holding the shaft. Carefully release spring compressor tension gradually and evenly. Verify spring is seated correctly at both ends before fully removing compressor tool.
9. 9

   Install strut assembly into vehicle
   With assistance or using the floor jack, lift the new strut assembly up into the wheel well. Guide the upper mount studs through the strut tower holes while angling the lower end toward the knuckle mounting location. Thread upper strut tower nuts onto studs by hand and snug them, but do not fully tighten yet.
10. 10

    Connect lower strut mounting
    Using the floor jack, raise the knuckle assembly to align the strut lower mounting holes with the knuckle mounting holes. Insert the lower strut mounting bolts and thread nuts onto the opposite side. Hand-tighten only at this stage. Verify all components are properly aligned.
11. 11

    Reconnect stabilizer bar and brake components
    Reconnect the stabilizer bar end link to the strut if applicable. Reattach the brake line bracket to the strut mounting point. Reconnect the wheel speed sensor electrical connector and secure the sensor cable with any clips or brackets to the strut body. Ensure no wires or lines are pinched or kinked.
12. 12

    Torque all fasteners
    Following proper tightening sequence, torque all mounting fasteners. Tighten upper strut tower nuts first (working in a star pattern if multiple nuts), then lower strut-to-knuckle bolts, stabilizer link nut, and brake line bracket bolt. Since factory torque specifications are not available in this database, you must obtain proper torque values from Rivian service documentation or consult a professional before tightening. Do not guess torque values on safety-critical suspension components.
    ⚠️Proper torque specifications are critical for safety. Under-torquing can result in fastener loosening and component separation. Over-torquing can result in fastener or component failure. Do not proceed without verified torque specifications.
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel and thread lug nuts by hand. Lower the vehicle until the tire just touches the ground but weight is still on jack stands. Torque wheel lug nuts to specification in a star pattern (typically 125-150 ft-lbs for this vehicle, but verify with manufacturer documentation). Fully lower vehicle and remove jack stands. Bounce the rear of the vehicle several times to settle suspension.

Reassembly

1. Reinstall all interior trim panels and upper strut tower covers removed during disassembly
2. Reconnect 12V battery negative terminal
3. If vehicle is equipped with electronic suspension controls or adaptive damping, initialization procedure may be required using Rivian diagnostic software

Verification

• Start vehicle and verify no warning lights related to suspension or wheel speed sensors are illuminated
• Perform a visual inspection underneath vehicle to confirm all components are properly secured and no parts are hanging or loose
• Test drive vehicle in a safe area at low speed, listening for any unusual noises and feeling for vibrations or handling issues
• Check that vehicle rides level front-to-rear and side-to-side
• After 50-100 miles of driving, re-torque all suspension fasteners to specification and verify nothing has loosened
• Professional wheel alignment is REQUIRED after suspension component replacement to ensure proper handling and tire wear

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