Front Suspension Rebuild

Complete rebuild of the front suspension system including control arms, ball joints, tie rods, and strut assemblies for the Rivian EDV 500 commercial van.

Warnings

Tools required

Parts

• Front strut assemblies (left and right) × 2 — Use OEM Rivian specification
• Front upper control arms (left and right) × 2 — Use OEM Rivian specification
• Front lower control arms (left and right) × 2 — Use OEM Rivian specification
• Outer tie rod ends (left and right) × 2 — Use OEM Rivian specification
• Inner tie rod ends (left and right) × 2 — Use OEM Rivian specification
• Sway bar end links (left and right) × 2 — Use OEM Rivian specification
• Ball joint set (upper and lower) × 4 — Use OEM Rivian specification
• Control arm bushings × 8 — Use OEM Rivian specification
• Strut mount bearings × 2 — Use OEM Rivian specification
• Wheel hub nuts × 2 — Use OEM Rivian specification
• Castle nuts for tie rods × 4 — Use OEM Rivian specification
• Cotter pins × 8 — Assorted sizes

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V auxiliary battery negative terminal located in front trunk area
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle using floor jack at designated front lift point
5. Support vehicle on jack stands placed at frame rail lift points
6. Remove both front wheels completely
7. Spray all suspension fasteners with penetrating oil and allow to soak
8. Take reference photos of suspension geometry and ride height for reassembly
9. Place drain pan under work area to catch any residual fluids from components

Procedure

1. 1

   Disconnect steering components
   Remove cotter pins from outer tie rod castle nuts on both sides. Using a tie rod end separator, disconnect outer tie rod ends from steering knuckles. Remove tie rod locking nuts and unthread outer tie rods, counting exact number of turns for reinstallation reference. Mark inner tie rod position on steering rack boot with paint marker.
2. 2

   Remove sway bar end links
   Locate sway bar end links connecting the sway bar to lower control arms. Hold the ball stud with an Allen key to prevent spinning while removing the retaining nuts from both top and bottom. Remove end links from both sides completely.
3. 3

   Disconnect ABS wheel speed sensors
   Locate ABS wheel speed sensor connectors near each front strut tower. Disconnect electrical connectors and carefully unclip sensor wiring from control arms and strut bodies. Do not allow sensors to hang or contact rotating components.
4. 4

   Remove brake caliper assemblies
   Remove brake caliper mounting bolts (typically two per caliper). Carefully lift calipers off brake rotors without allowing brake hoses to stretch or kink. Secure calipers to frame or suspension with mechanics wire or zip ties - never let them hang by brake hoses.
5. 5

   Separate lower ball joints
   Remove lower ball joint castle nut and cotter pin from each side. Use ball joint separator or pickle fork to separate lower ball joint from steering knuckle. Apply force carefully to avoid damaging the knuckle. Once separated, support the knuckle and hub assembly to prevent strain on upper ball joint.
6. 6

   Remove lower control arms
   Locate lower control arm mounting bolts at frame attachment points (typically two bolts per arm - front and rear bushings). Support the lower control arm with a floor jack. Remove mounting bolts and carefully lower the control arm. Note the orientation and position of any shims or alignment washers for reinstallation. Repeat for opposite side.
   ⚠Control arms may drop suddenly when final bolt is removed. Keep hands clear of pinch points.
7. 7

   Disconnect upper ball joints and remove knuckles
   Remove upper ball joint castle nut and cotter pin. Use ball joint separator to disconnect upper ball joint from knuckle. With both ball joints disconnected, remove steering knuckle and hub assembly completely. Set aside on clean workspace.
8. 8

   Remove strut assemblies
   From inside engine bay, locate strut tower mounting nuts (typically three nuts per strut at top). Support strut assembly from below with floor jack. Remove upper strut mounting nuts while supporting the strut. Lower jack and remove strut assembly downward through lower control arm area. Repeat for opposite side.
   ⚠Strut assemblies are heavy and awkward. Have an assistant help guide them out to prevent damage to fenders or surrounding components.
9. 9

   Remove upper control arms
   Locate upper control arm frame mounting bolts (typically two per arm). Mark or photograph exact position of any cam bolts or eccentric washers used for alignment adjustment. Remove mounting bolts and extract upper control arms from both sides.
10. 10

    Inspect and clean mounting points
    Thoroughly inspect all frame mounting points for damage, cracks, or excessive corrosion. Clean all threaded holes with wire brush. Inspect steering knuckles and hub assemblies for damage - replace if any cracks or deformation found. Clean ball joint tapers in knuckles with solvent and wire brush.
11. 11

    Install new upper control arms
    Install new upper control arms to frame mounting points. Install bolts finger-tight only at this stage - do not torque. If cam bolts were present, install them in the same orientation as noted during removal. Ensure any alignment shims are properly positioned.
12. 12

    Install new strut assemblies
    If replacing complete strut assemblies (not rebuilding existing), install new strut mount bearings to strut towers if not pre-installed. Guide new strut assemblies up through lower control arm area. Align upper mounting studs with strut tower holes. Install upper mounting nuts finger-tight. Leave lower strut connections disconnected at this stage.
13. 13

    Install new lower control arms and connect ball joints
    Position new lower control arms at frame mounting points. Install mounting bolts finger-tight. Position steering knuckles and connect new lower ball joints to knuckles - ensure ball joint tapers are clean and seat fully. Install new castle nuts and tighten until cotter pin hole aligns, then install new cotter pins.
14. 14

    Connect upper ball joints and secure struts
    Connect new upper ball joints to steering knuckles. Install new castle nuts and tighten until cotter pin holes align, install new cotter pins. Connect lower portion of strut assemblies to steering knuckles or lower control arms (depending on EDV 500 design). Install all fasteners but leave at specified torque for after vehicle is at ride height.
15. 15

    Install remaining components and torque all fasteners
    Install new inner and outer tie rod ends - thread outer tie rods the same number of turns as counted during removal. Install castle nuts and new cotter pins. Install new sway bar end links and tighten. Reinstall brake calipers with new mounting bolts if specified. Reconnect ABS sensors and secure wiring. Lower vehicle to ground so suspension is at normal ride height. With suspension loaded, torque all suspension fasteners to manufacturer specifications in this sequence: upper control arm frame bolts, lower control arm frame bolts, strut mounting bolts, ball joint nuts (if not already castle-nut tightened), and tie rod castle nuts. Install wheels and torque lug nuts in star pattern.
    ℹ️All suspension fasteners must be torqued with vehicle at ride height (wheels on ground or suspension compressed to simulate ride height). Torquing with suspension hanging will preload bushings incorrectly and cause premature failure.

Reassembly

1. Reconnect 12V auxiliary battery negative terminal
2. Pump brake pedal several times to reseat brake caliper pistons
3. Check brake fluid level in reservoir and top off with DOT 4 if needed
4. Start vehicle and verify no warning lights on dashboard related to ABS or suspension
5. Test steering for full range of motion without binding or unusual noises

Verification

• Perform visual inspection of all installed components - verify no loose fasteners or disconnected sensors
• Test drive vehicle at low speed in safe area - verify steering response and absence of clunking or rattling
• Check for any fluid leaks around brake calipers
• Immediately schedule professional four-wheel alignment at qualified shop with Rivian specifications
• After 50-100 miles, re-torque all suspension fasteners to verify none have loosened
• Monitor tire wear pattern over next 500 miles to confirm proper alignment was achieved

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