This procedure covers the removal and replacement of the front upper control arm on a 2023 Rivian EDV 500 electric delivery van with dual motor all-wheel drive.

Warnings

Tools required

Parts

• Front upper control arm assembly × 1 — Use OEM Rivian specification
• Upper control arm frame mounting bolts × 2 — Use OEM specification
• Ball joint castle nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery negative terminal to prevent electrical issues
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Raise front of vehicle using floor jack at designated front lift point
6. Support vehicle securely on jack stands at frame lift points
7. Remove front wheel on affected side completely
8. Spray all suspension fasteners with penetrating oil and allow to soak for 15 minutes if corrosion is present
9. Photograph or mark the orientation of adjustable components for reference

Procedure

1. 1

   Support suspension at ride height
   Position a floor jack or suspension support jack under the lower control arm near the ball joint. Raise jack until suspension is at approximately normal ride height. This removes tension from the upper control arm and prevents the suspension from dropping when the upper ball joint is disconnected.
2. 2

   Remove upper ball joint cotter pin
   Locate the upper ball joint castle nut where the control arm connects to the steering knuckle. Straighten and remove the cotter pin using pliers or a cotter pin removal tool. Discard the old cotter pin as it should not be reused.
3. 3

   Remove upper ball joint castle nut
   Using an 18mm or 19mm socket (verify size), remove the castle nut securing the upper ball joint to the steering knuckle. Keep the nut for reference when torquing the new installation. Note: Do not fully separate the ball joint yet.
4. 4

   Separate upper ball joint from knuckle
   Use a ball joint separator tool or pickle fork to separate the upper control arm ball joint from the steering knuckle. Insert the separator between the knuckle and control arm, then strike or press to break the taper free. Be careful not to damage the CV boot or brake components. Once separated, carefully lower the knuckle assembly away from the control arm.
   ⚠The ball joint will separate suddenly. Ensure the suspension is properly supported to prevent the knuckle from falling.
5. 5

   Access and identify frame mounting bolts
   Locate the two frame mounting bolts that secure the upper control arm to the vehicle frame rail. These are typically located at the front and rear of the control arm pivot points. On the Rivian EDV, these may be accessed from above in the wheel well or may require reaching through the frame opening. Clean the bolt heads and surrounding area with a wire brush.
6. 6

   Mark control arm position
   Before removing mounting bolts, use a marker or scribe to mark the position of any eccentric cams, shims, or adjustment points on the control arm relative to the frame. This provides a reference point for initial alignment when installing the new control arm and can save time during alignment.
7. 7

   Remove rear frame mounting bolt
   Using a 21mm socket and breaker bar (size may vary - verify before applying force), remove the rear control arm frame mounting bolt. This bolt may require significant force to loosen. Support the control arm with your hand to prevent it from rotating as the bolt is removed. Remove the bolt completely and inspect for any shims, washers, or adjustment hardware that must be transferred to the new control arm.
8. 8

   Remove front frame mounting bolt
   Using the same socket size, remove the front control arm frame mounting bolt. Once both bolts are removed, carefully lower and remove the upper control arm from the vehicle. Inspect the mounting points on the frame for damage, corrosion, or wear. Clean the mounting surfaces if necessary.
9. 9

   Compare and prepare new control arm
   Place the old control arm next to the new control arm and verify they are identical in design, ball joint orientation, and mounting hole positions. Transfer any shims, washers, or adjustment hardware from the old control arm to the new one in the same positions as marked earlier. Inspect the ball joint boot on the new control arm for any damage that may have occurred during shipping.
10. 10

    Install new control arm to frame
    Position the new upper control arm into place on the frame mounting points, aligning it with the reference marks made during disassembly. Insert the front frame mounting bolt first, threading it by hand to hold the control arm in position. Then insert the rear frame mounting bolt. Do not fully tighten either bolt yet - leave them hand-tight to allow for adjustment.
11. 11

    Connect ball joint to steering knuckle
    Raise the suspension support jack slightly to lift the steering knuckle assembly up to the ball joint stud. Align the ball joint stud with the tapered hole in the knuckle and press or tap the knuckle onto the stud until it is fully seated. Install the castle nut and tighten it firmly by hand, ensuring the ball joint taper is properly engaged.
12. 12

    Torque upper ball joint castle nut
    Using a torque wrench, tighten the upper ball joint castle nut to the manufacturer's specification (specification not available in database - consult Rivian service manual). After reaching proper torque, continue tightening if necessary until the nearest castle slot aligns with the cotter pin hole in the stud. Never back off the nut to align the cotter pin hole. Install a new cotter pin through the castle nut and stud, then bend the ends of the pin to secure it.
13. 13

    Torque frame mounting bolts at ride height
    With the suspension still supported at normal ride height by the jack, torque the front and rear control arm frame mounting bolts to manufacturer's specification (specification not available in database - consult Rivian service manual). It is critical that these bolts are torqued with the suspension at ride height to prevent binding in the bushings. Torque in a cross-pattern if applicable, and verify both bolts are fully seated and torqued.
    ⚠Control arm mounting bolts must be torqued at ride height to prevent premature bushing failure and binding.
14. 14

    Remove suspension support and reinstall wheel
    Carefully lower and remove the suspension support jack from under the lower control arm. Inspect all connections one final time. Reinstall the wheel and thread the lug nuts by hand. Lower the vehicle until the wheel just touches the ground but the suspension is not fully loaded. Torque the lug nuts to specification in a star pattern.

Reassembly

1. Ensure all fasteners are torqued to proper specifications using Rivian service documentation
2. Verify the new cotter pin is properly installed and bent to prevent backing out
3. Check that no tools or parts were left in the wheel well or suspension area
4. Reconnect the 12V auxiliary battery negative terminal
5. Remove jack stands and lower vehicle completely to the ground

Verification

• Start vehicle and verify no warning lights appear on the dashboard related to suspension or drivetrain
• Turn steering wheel lock-to-lock while stationary and listen for any unusual noises from the upper control arm area
• Perform a slow test drive in a safe area, checking for abnormal handling, pulling, or noise
• Visually inspect the new control arm installation for proper alignment and seating of all components
• Schedule a professional front-end alignment as soon as possible - this is mandatory after upper control arm replacement

More procedures for this vehicle