This procedure covers the removal and replacement of the front sway bar bushings on a 2023 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Front sway bar bushing set (left and right) × 1 — Use OEM specification
• Sway bar bushing bracket bolts (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. No battery disconnect is required for this procedure
4. Allow suspension to settle at ride height for at least 5 minutes before beginning work
5. Apply penetrating lubricant to all sway bar bushing bracket bolts and allow to soak for 10-15 minutes

Procedure

1. 1

   Raise and support vehicle
   Raise the front of the vehicle using a floor jack at the designated front jacking point. Once raised to working height, place jack stands under the frame rails at the manufacturer-specified support points. Lower the vehicle onto the jack stands. Verify stability before proceeding. The front wheels should remain on the ground or be lowered after supporting the frame to relieve sway bar tension.
   ⚠Consult owner's manual for proper jack and jack stand placement points to avoid damaging the battery pack or drive units.
2. 2

   Access sway bar bushings
   Locate the front sway bar, which runs laterally across the front suspension behind the front bumper assembly. Identify the two sway bar bushing brackets that secure the sway bar to the subframe or front cross member. The bushings are typically located near the center of the sway bar on either side of the vehicle centerline.
3. 3

   Remove driver side bushing bracket
   Beginning with the driver side, remove the bolts securing the sway bar bushing bracket to the subframe. There are typically two bolts per bracket. Use a socket and ratchet or combination wrench to remove these bolts completely. Set bolts aside in a clean location for inspection. Carefully remove the bracket from the sway bar.
4. 4

   Remove driver side bushing
   Once the bracket is removed, the bushing will be loose on the sway bar. The bushing is typically split and can be removed by spreading it open and sliding it off the bar. If the bushing is degraded or stuck, carefully cut it away using a utility knife, taking care not to damage the sway bar surface. Inspect the sway bar for damage, corrosion, or wear.
5. 5

   Clean driver side mounting area
   Use a wire brush to clean the sway bar surface where the bushing sits, removing any rubber residue, corrosion, or debris. Also clean the mounting surface on the subframe and inspect the bracket for cracks or damage. Clean the bracket bolt threads and inspect for damage.
6. 6

   Install driver side new bushing
   Apply a light coating of silicone lubricant spray to the inside of the new bushing and the cleaned sway bar surface. Position the new bushing on the sway bar in the correct location, ensuring any orientation marks or splits face the proper direction (typically split faces downward or rearward). The bushing should be centered in the wear area on the bar.
7. 7

   Install driver side bracket
   Position the bushing bracket over the installed bushing, ensuring the bushing seats properly in the bracket. Align the bracket with the mounting holes on the subframe. Install the bracket bolts finger-tight initially to allow for adjustment. Ensure the bushing is not pinched or twisted.
8. 8

   Tighten driver side bracket bolts
   Tighten the bracket bolts in an alternating pattern to ensure even pressure on the bushing. Since no specific torque values are provided in the database, tighten bolts securely following manufacturer specifications from a service manual or using standard automotive bushing bracket torque values (typically 35-50 ft-lbs for this application, but verify with OEM documentation).
9. 9

   Remove passenger side bushing bracket
   Repeat the removal process for the passenger side bushing bracket. Remove both bracket bolts and carefully remove the bracket from the sway bar. Set bolts aside for inspection.
10. 10

    Remove and replace passenger side bushing
    Remove the old bushing from the sway bar using the same method as the driver side. Clean the sway bar surface and mounting area with a wire brush. Apply silicone lubricant and install the new bushing in the correct orientation on the sway bar.
11. 11

    Install passenger side bracket and tighten
    Position the bracket over the new bushing and align with mounting holes. Install bracket bolts finger-tight, verify bushing alignment, then tighten bolts in an alternating pattern to manufacturer specifications.
12. 12

    Verify installation
    Visually inspect both bushings to ensure they are properly seated in their brackets and not twisted or pinched. Verify all bracket bolts are tight and secure. Check that the sway bar moves freely through the bushings without binding.
13. 13

    Lower vehicle
    Carefully raise the vehicle slightly with the floor jack to unload the jack stands. Remove jack stands and slowly lower the vehicle to the ground. Remove wheel chocks.

Reassembly

1. No additional reassembly required beyond bracket installation
2. Ensure all tools and parts are removed from under the vehicle before test driving

Verification

• Start the vehicle and turn the steering wheel lock-to-lock while stationary to verify no unusual noises from the sway bar area
• Test drive the vehicle at low speed over bumps and during turns to verify proper sway bar operation and absence of clunking or rattling noises
• After 50-100 miles of driving, re-inspect bracket bolt tightness and verify no bushing movement or degradation
• Check for even tire wear patterns after several hundred miles to ensure proper suspension geometry

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