This procedure covers the removal and replacement of the rear upper control arm on a 2023 Rivian EDV 500, requiring suspension disassembly and wheel alignment upon completion.

Warnings

Tools required

Parts

• Rear upper control arm assembly × 1 — Use OEM Rivian specification
• Upper control arm mounting bolts/nuts × 1 — Use OEM specification or inspect for reuse
• Ball joint castle nut (if applicable) × 1 — Use OEM specification
• Cotter pin (if applicable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks at front wheels
3. Disconnect 12V battery negative terminal and wait 2 minutes for system discharge
4. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
5. Raise rear of vehicle using floor jack at designated jacking points
6. Support vehicle securely on jack stands at frame rails rated for vehicle weight
7. Remove rear wheel completely
8. Spray all suspension fasteners with penetrating lubricant and allow to soak for 10-15 minutes

Procedure

1. 1

   Support suspension and relieve load
   Position a floor jack under the rear lower control arm or knuckle assembly to support the suspension at ride height. This prevents the suspension from dropping when the upper control arm is disconnected and keeps tension off the components.
2. 2

   Remove wheel speed sensor wire (if routed on control arm)
   Inspect the upper control arm area for any ABS wheel speed sensor wiring or clips attached to the control arm. Carefully disconnect any clips or routing brackets to prevent damage to the wiring harness during removal.
3. 3

   Disconnect upper ball joint from knuckle
   Locate the upper ball joint connection at the steering knuckle. Remove the castle nut (and cotter pin if equipped). Use a ball joint separator tool to break the taper connection between the ball joint stud and knuckle. Do not use excessive force that could damage the knuckle or surrounding components.
4. 4

   Mark alignment cam positions (if equipped)
   If the control arm mounting points include alignment cams or eccentric bolts, use a paint marker or scribe to mark the current position of all adjustment points relative to the mounting bracket. This provides a baseline for initial reassembly alignment.
5. 5

   Remove front control arm mounting bolt
   Locate the front mounting point where the upper control arm attaches to the frame or subframe. Support the control arm with one hand and remove the mounting bolt and any washers or spacers. Note the orientation and position of all hardware for reinstallation.
6. 6

   Remove rear control arm mounting bolt
   Locate the rear mounting point of the upper control arm. Remove the rear mounting bolt, washers, and any bushings or spacers. Keep track of all hardware orientation. The control arm should now be free from the vehicle.
7. 7

   Remove and inspect upper control arm
   Carefully remove the upper control arm from the vehicle. Inspect the ball joint boot for tears, check bushings for cracking or separation, and examine mounting points for elongation or damage. Transfer any reusable hardware if the new arm does not include it.
8. 8

   Prepare new control arm and mounting points
   Clean all mounting surfaces on the frame and knuckle with a wire brush to remove rust and debris. Inspect the mounting bolt holes for damage or thread wear. If the new control arm includes serviceable bushings or ball joint, verify they are properly installed and lubricated per manufacturer specifications.
9. 9

   Install new control arm to frame mounts
   Position the new upper control arm into the mounting brackets, aligning the front mounting point first. Insert the front mounting bolt with all washers and spacers in their original orientation. Do not fully tighten. Install the rear mounting bolt with hardware in original positions. Hand-tighten both bolts to hold the arm in position.
10. 10

    Connect upper ball joint to knuckle
    Raise or lower the floor jack supporting the suspension to align the ball joint stud with the hole in the steering knuckle. Insert the ball joint stud into the knuckle and install the castle nut. Tighten to specification (must obtain from Rivian service information). Install new cotter pin if applicable.
11. 11

    Torque control arm mounting bolts at ride height
    With the suspension still supported by the floor jack at normal ride height, torque the front and rear upper control arm mounting bolts to manufacturer specification. This is critical - control arm bushings must be torqued at ride height to prevent premature bushing failure. You must obtain these torque values from official Rivian service documentation.
12. 12

    Reinstall wheel speed sensor routing
    Reattach any ABS wheel speed sensor wiring or harness clips to the control arm or mounting brackets. Ensure the wiring has adequate slack and will not be pinched or stretched during suspension travel.
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel and thread lug nuts by hand. Lower the vehicle until the tire just contacts the ground. Torque the lug nuts to specification in a star pattern (obtain from Rivian service information). Fully lower the vehicle and remove jack stands.

Reassembly

1. Reconnect the 12V battery negative terminal
2. Perform a visual inspection of all mounting points to verify proper installation
3. Test suspension articulation by bouncing the rear of the vehicle to ensure no binding or unusual noises
4. All control arm bushing bolts must be torqued at ride height to prevent premature failure

Verification

• Verify all fasteners are properly torqued according to Rivian service specifications
• Confirm no suspension components contact the wheels during full steering lock and suspension articulation
• Check for any unusual noises when driving over small bumps at low speed
• Schedule four-wheel alignment immediately - camber, caster, and toe settings will be affected by control arm replacement
• After 50-100 miles, re-check all mounting bolt torque values
• Verify even tire wear pattern after 500-1000 miles to confirm proper alignment

More procedures for this vehicle