This procedure covers the removal and installation of the front or rear subframe on the 2023 Rivian EDV 500 electric delivery van, including suspension and drivetrain component disconnection.

Warnings

Tools required

Parts

• Subframe mounting bolts × 1 — Use OEM specification
• Control arm mounting hardware × 1 — Use OEM specification
• Differential mounting hardware (if applicable) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil (front differential) — 1.5 qt
• 75W-90 GL-5 Gear Oil (rear differential) — 2 qt

Preparation

1. Perform high-voltage system shutdown procedure and install HV lockout device according to Rivian service manual
2. Verify high-voltage system is de-energized using appropriate voltage testing equipment
3. Raise vehicle on lift to working height and ensure proper support on frame rails
4. Remove all four wheels and tires
5. Document or photograph all electrical connector locations and suspension component orientations
6. Place drain pans under differential if removing rear subframe or front subframe with front differential

Procedure

1. 1

   Disconnect battery and electrical systems
   Disconnect the 12V auxiliary battery negative terminal. Locate and disconnect all electrical connectors attached to components mounted on the subframe, including wheel speed sensors, differential temperature sensors (if equipped), and any wiring harnesses routed along the subframe. Label each connector for reinstallation.
2. 2

   Remove brake calipers and rotors
   Remove brake calipers from the steering knuckles or axle carriers and secure them to the chassis using mechanics wire - do not let them hang by brake hoses. Remove brake rotors to provide clearance for suspension work.
3. 3

   Disconnect steering linkage (front subframe only)
   If removing the front subframe, disconnect the steering gear from the intermediate shaft by removing the pinch bolt. Remove the outer tie rod ends from the steering knuckles using a tie rod separator tool. Mark the tie rod adjustment position before removal.
4. 4

   Disconnect stabilizer bar links
   Remove the stabilizer bar end link mounting nuts from both sides of the vehicle. Disconnect the stabilizer bar from the links, allowing the bar to hang freely or removing it completely if it interferes with subframe removal.
5. 5

   Disconnect control arms and suspension
   Remove the lower control arm mounting bolts at the subframe. Remove the upper control arm mounting bolts if they attach to the subframe rather than the body. Support the steering knuckle/hub assembly with a jack stand or mechanics wire to prevent damage to CV axles and wheel bearings. Remove shock absorber lower mounting bolts from subframe if applicable.
6. 6

   Disconnect drive axles or driveshafts
   If the subframe being removed contains a differential, drain the differential fluid into appropriate container. Remove the CV axle mounting bolts from the differential output flanges or remove the axles completely from the differential. Support axles to prevent damage to boots and joints. For rear subframe, disconnect the driveshaft from the rear differential pinion flange.
7. 7

   Disconnect differential mounts (if equipped)
   If the subframe contains an integrated motor/differential unit, disconnect all motor mounting bolts and electrical connections to the motor assembly. Verify all cooling lines to the motor/differential are disconnected or capped. Support the motor assembly weight before removing final mounting bolts.
8. 8

   Support subframe with transmission jack
   Position a hydraulic transmission jack or dedicated subframe support fixture under the center of the subframe. Raise the jack until it makes solid contact and slightly loads the subframe. Secure the subframe to the jack with straps or chains to prevent shifting during removal.
9. 9

   Remove subframe mounting bolts
   Locate all subframe-to-body mounting bolts, typically four to six main mounting points. Have an assistant support the subframe or verify jack stability. Remove the subframe mounting bolts in a cross-pattern sequence to maintain even loading. Note the position and orientation of any alignment dowels or washers.
10. 10

    Lower and remove subframe
    Carefully lower the transmission jack, monitoring for any still-connected components, wires, or hoses. Guide the subframe down and away from the vehicle body, checking clearance at the front, rear, and sides. Once fully lowered, roll the jack and subframe assembly out from under the vehicle.
11. 11

    Inspect and prepare for installation
    Inspect the subframe mounting points on the vehicle body for damage, corrosion, or elongated bolt holes. Clean all mounting surfaces with a wire brush and brake cleaner. Inspect the subframe itself for cracks, damage, or worn bushings. Replace any damaged components before reinstallation. Clean all bolt threads and apply anti-seize to bolt threads (but not to torque-critical fasteners requiring thread locker).
12. 12

    Position new or repaired subframe
    Place the subframe onto the transmission jack and secure with straps. Roll the assembly under the vehicle and align with mounting points on the body. Raise the subframe slowly, using alignment pins or drift punches to guide the subframe into proper position with body mounting holes. Have an assistant help guide the subframe if necessary.
13. 13

    Install subframe mounting bolts
    Install all subframe mounting bolts finger-tight, ensuring proper engagement of any alignment dowels or locating features. Verify the subframe is seated properly against all mounting surfaces. Tighten subframe mounting bolts in a cross-pattern sequence to ensure even loading. Apply thread locker to bolts as specified by manufacturer. Note: Consult Rivian service manual for exact torque specifications as none are provided in this database.
14. 14

    Reconnect suspension and drivetrain components
    Reconnect all control arms, shock absorbers, and stabilizer bar links to the subframe. Reconnect the steering gear and tie rod ends if working on front subframe. Reinstall drive axles to differential output flanges or reinsert into differential housing with new circlips. Reconnect driveshaft to rear differential if applicable. Tighten all fasteners to specification.
15. 15

    Refill fluids and reconnect electrical
    Refill the differential with appropriate 75W-90 GL-5 gear oil to specification (1.5 quarts front, 2.0 quarts rear). Reconnect all electrical connectors to sensors and motor assemblies. Reinstall brake rotors and calipers. Install wheels and torque lug nuts to specification. Remove HV lockout device and reconnect 12V battery.

Reassembly

1. Torque all fasteners to Rivian specifications using a calibrated torque wrench
2. Ensure all electrical connectors are fully seated and locked
3. Verify differential fill levels through fill ports after vehicle is on level ground
4. Double-check that all suspension components move freely without binding
5. Verify no tools or parts were left in the work area

Verification

• Perform a visual inspection of all subframe mounting points to ensure proper seating and bolt engagement
• Lower vehicle and perform a bounce test on each corner to verify suspension operation
• Start vehicle and verify no warning lights related to suspension, drivetrain, or high-voltage systems
• Test drive vehicle at low speed in a safe area to check for unusual noises, vibrations, or handling issues
• Schedule four-wheel alignment immediately after subframe installation to ensure proper tire wear and handling
• Re-check all subframe mounting bolt torque after 50-100 miles of driving

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