This procedure covers the removal and replacement of the front sway bar (stabilizer bar) on a 2023 Rivian EDV 500 electric delivery van with dual motor AWD.

Warnings

Tools required

Parts

• Front sway bar (stabilizer bar) × 1 — Use OEM specification
• Sway bar bushings × 2 — Use OEM specification
• Sway bar end link bushings/hardware kit × 2 — Use OEM specification
• Sway bar mounting bracket bolts × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Lift front of vehicle using appropriate lift points per Rivian service manual
4. Support vehicle on jack stands rated for commercial vehicle weight
5. Remove both front wheels
6. Inspect sway bar, end links, and bushings for wear or damage to confirm replacement necessity
7. Apply penetrating oil to all sway bar mounting fasteners and allow to soak for 10-15 minutes

Procedure

1. 1

   Disconnect left front sway bar end link
   Locate the left front sway bar end link connecting the sway bar to the lower control arm or strut assembly. Using appropriate wrenches, hold the end link stud while loosening the upper nut connecting to the sway bar. Remove the nut and washer, then remove the lower fastener connecting to the control arm/strut. Remove the end link from the vehicle.
2. 2

   Disconnect right front sway bar end link
   Repeat the same procedure for the right front sway bar end link. Hold the end link stud while loosening the upper nut connecting to the sway bar. Remove the nut and washer, then remove the lower fastener. Remove the end link from the vehicle. The sway bar is now free from the suspension components.
3. 3

   Remove left sway bar bushing bracket
   Locate the left side sway bar bushing bracket that secures the bar to the subframe or chassis. Remove the two or more bolts securing the bracket to the frame. Note the orientation and position of any washers or spacers. Carefully remove the bracket and set aside. The bushing may remain with the bracket or on the bar.
4. 4

   Remove right sway bar bushing bracket
   Locate the right side sway bar bushing bracket. Remove the bolts securing the bracket to the frame, noting the orientation of all components. Remove the bracket and bushing assembly. The sway bar should now be free to be removed from the vehicle.
5. 5

   Remove front sway bar from vehicle
   Carefully maneuver the front sway bar out from its mounting position. The bar may need to be rotated or angled to clear suspension components, the front axle assembly, and steering linkage. On the EDV 500, pay attention to clearance around the front motor housing and drive unit. Support the bar as you remove it to prevent damage to surrounding components.
6. 6

   Inspect and prepare mounting points
   With the sway bar removed, inspect the mounting points on the subframe for damage, corrosion, or wear. Use a wire brush to clean the mounting surfaces. Inspect the bracket bolt holes for thread damage or elongation. Check that all mounting surfaces are flat and free of debris.
7. 7

   Prepare new sway bar and bushings
   Install new bushings onto the replacement sway bar in the correct orientation. The split in the bushing should face the appropriate direction per manufacturer specifications (typically toward the rear of the vehicle). Apply a light coating of silicone lubricant to the inside of the bushings if recommended. Ensure bushings are centered on the bar at the mounting locations.
8. 8

   Install new front sway bar
   Carefully maneuver the new sway bar into position, routing it through the suspension and around the front drive unit. Align the bar so the end link mounting points are positioned correctly relative to the control arms or struts, and the bushing locations align with the frame mounting brackets. Support the bar to hold it in position.
9. 9

   Install right sway bar bushing bracket
   Position the right side bushing bracket over the bushing and align it with the frame mounting holes. Install the mounting bolts and hand-tighten initially. Ensure the bushing is properly seated in the bracket and the bracket is flush against the mounting surface.
10. 10

    Install left sway bar bushing bracket
    Position the left side bushing bracket over the bushing and align it with the frame mounting holes. Install the mounting bolts and hand-tighten. Verify both brackets are properly positioned and the sway bar is centered in the vehicle with equal clearance on both sides.
11. 11

    Torque sway bar bracket bolts
    Using a torque wrench, tighten the sway bar bracket mounting bolts to the appropriate specification. Since vehicle-specific torque values are not available in the database, consult Rivian service documentation. Typical values for M12 fasteners into subframe are 70-90 Nm. Tighten in a cross pattern if multiple bolts per bracket.
12. 12

    Install left front end link
    Position the new left front end link between the sway bar and the lower control arm or strut mounting point. Install the lower fastener and hand-tighten. Install the upper fastener with washer connecting to the sway bar and hand-tighten. Hold the end link stud with a wrench while tightening the nuts.
13. 13

    Install right front end link
    Position the new right front end link between the sway bar and the mounting point. Install both the lower and upper fasteners with washers and hand-tighten. Hold the end link stud with a wrench while tightening the nuts.
14. 14

    Torque end link fasteners
    Using a torque wrench, tighten all end link fasteners to specification. Hold the stud with a wrench to prevent rotation while torquing the nuts. Consult Rivian service documentation for specific values; typical specifications for end link fasteners are 50-65 Nm. Verify all connections are secure and properly seated.
15. 15

    Final inspection and reinstall wheels
    Perform a visual inspection of all connections, ensuring all fasteners are tight and properly torqued. Check for adequate clearance between the sway bar and all surrounding components throughout the suspension travel range. Reinstall both front wheels and torque lug nuts to Rivian specification (typically 200 Nm for commercial vehicles, but verify with manufacturer documentation).

Reassembly

1. Torque all fasteners to manufacturer specifications
2. Ensure sway bar bushings are properly seated and centered
3. Verify adequate clearance between sway bar and all components
4. Reinstall wheels and torque lug nuts to specification

Verification

• Lower vehicle to ground and bounce each front corner to verify sway bar operation
• Listen for any clunking or rattling noises that would indicate loose components
• Verify equal ride height on both sides of vehicle
• Test drive vehicle at low speed and perform gentle turning maneuvers to confirm proper sway bar function
• Check for unusual handling characteristics or body roll
• Re-inspect all fasteners after test drive and re-torque if necessary
• Schedule alignment check if handling feels abnormal

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