This procedure covers the removal and replacement of the upper control arm on a 2023 Rivian EDV 500 Dual Motor AWD electric delivery van.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification
• Upper ball joint castle nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification
• Control arm mounting bolts × 2 — Use OEM specification or reuse if not damaged

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts on the side being serviced while vehicle is on the ground
4. Locate proper jacking points per Rivian service manual for EDV 500
5. Raise vehicle and support securely on jack stands rated for EV weight
6. Remove wheel and tire assembly
7. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes
8. Take photos of suspension geometry for reference during reassembly

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the lower control arm to support the suspension assembly and relieve tension on the upper control arm. Raise the jack just enough to slightly compress the suspension, simulating normal ride height. This prevents the suspension from dropping when the upper control arm is disconnected.
2. 2

   Remove the wheel speed sensor if obstructing
   If the ABS wheel speed sensor or wiring interferes with upper control arm removal, carefully disconnect the electrical connector and remove any mounting clips or brackets. Route the sensor wire away from the work area and secure it to prevent damage.
3. 3

   Remove the upper ball joint cotter pin and castle nut
   Straighten and remove the cotter pin from the upper ball joint castle nut. Remove the castle nut completely from the ball joint stud. Note the number of threads visible above the knuckle for reference during reassembly.
4. 4

   Separate the upper ball joint from the steering knuckle
   Use a ball joint separator tool or pickle fork to separate the upper ball joint taper from the steering knuckle. Position the tool between the control arm and knuckle, taking care not to damage the CV boot or brake components. Apply steady pressure until the taper releases with a popping sound. If using a pickle fork, note that it may damage the ball joint boot, requiring ball joint replacement.
5. 5

   Mark the control arm position
   Before removing the control arm mounting bolts, mark the position of the control arm relative to the frame mounting points using paint or a scribe. This provides a rough starting point for alignment during reassembly and helps ensure proper installation orientation.
6. 6

   Remove the front control arm mounting bolt
   Locate the front mounting bolt that secures the upper control arm to the frame. Support the control arm with one hand while removing the bolt completely with a socket and breaker bar. The bolt may be equipped with a cam washer or eccentric adjuster for alignment purposes; note the orientation for reassembly.
7. 7

   Remove the rear control arm mounting bolt
   Remove the rear mounting bolt that secures the upper control arm to the frame. Again, note any cam washers, eccentric adjusters, or shims present. These components are critical for maintaining proper alignment settings.
8. 8

   Remove the upper control arm
   With both mounting bolts removed, carefully maneuver the upper control arm out of the suspension assembly. It may be necessary to slightly raise or lower the floor jack supporting the lower control arm to create clearance. Inspect the mounting bushings and hardware for wear or damage.
9. 9

   Inspect and clean mounting surfaces
   Thoroughly clean the frame mounting points with a wire brush, removing any rust, dirt, or debris. Inspect the mounting holes for elongation, cracks, or damage. Check that threads in the frame (if applicable) are clean and undamaged. Apply anti-seize compound to the bolt threads and mounting surfaces.
10. 10

    Install the new upper control arm
    Position the new upper control arm into the frame mounting points, aligning it with the reference marks made during disassembly. Insert both mounting bolts finger-tight, ensuring any cam washers, eccentric adjusters, or shims are installed in their original positions and orientations. Do not fully tighten at this stage.
11. 11

    Connect the ball joint to the steering knuckle
    Adjust the floor jack height to align the upper ball joint stud with the hole in the steering knuckle. Insert the ball joint stud into the knuckle and install the new castle nut. Thread the nut until it is seated but not yet torqued.
12. 12

    Torque all fasteners to specification
    With the suspension at normal ride height (supported by the floor jack), torque the control arm mounting bolts and ball joint castle nut to manufacturer specifications. Since no torque values are provided in the database, consult the Rivian EDV 500 service manual for exact specifications. After torquing the castle nut, align the nearest slot with the cotter pin hole and install a new cotter pin, bending the ends to secure.
13. 13

    Reinstall wheel speed sensor components
    If the wheel speed sensor was removed, reinstall it in its original position and reconnect the electrical connector. Ensure all wiring clips and brackets are secured and that the sensor wire is properly routed away from moving suspension components and heat sources.
14. 14

    Remove jack support and reinstall wheel
    Carefully lower and remove the floor jack from under the lower control arm. Reinstall the wheel and tire assembly, threading the lug nuts by hand. Lower the vehicle until the tire just contacts the ground, then torque the lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.

Reassembly

1. Ensure all fasteners are torqued to specification with the suspension at normal ride height
2. Verify the cotter pin is properly installed and bent to prevent the castle nut from loosening
3. Confirm all electrical connections for wheel speed sensors are secure and properly routed
4. Double-check that no tools or parts were left in the wheel well or suspension area

Verification

• Test drive the vehicle in a safe area at low speed, listening for unusual noises from the suspension
• Check for proper steering feel and responsiveness with no binding or looseness
• Visually inspect all mounting points and fasteners after the test drive to ensure nothing has loosened
• Schedule a professional four-wheel alignment immediately, as camber, caster, and toe settings will be significantly altered
• After alignment, verify even tire wear patterns and proper vehicle tracking

More procedures for this vehicle