This procedure covers the removal and replacement of a front ABS wheel speed sensor on the 2024 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• ABS wheel speed sensor × 1 — Use OEM Rivian specification
• Sensor mounting bolt × 1 — Use OEM specification if damaged

Preparation

1. Connect diagnostic scan tool and verify which front wheel speed sensor has failed (left or right)
2. Clear any existing ABS fault codes and document them for reference
3. Park vehicle on level surface and apply parking brake
4. Place wheel chocks behind rear wheels
5. Verify high voltage system is deactivated and display shows vehicle is safe to service

Procedure

1. 1

   Remove front wheel
   Loosen the front wheel lug nuts while vehicle is on the ground. Raise the front of the vehicle using a floor jack at the designated lift point. Support with jack stands rated for the vehicle weight (minimum 6,000 lbs capacity per side). Remove the lug nuts and wheel completely.
2. 2

   Access sensor location
   Locate the ABS wheel speed sensor mounted to the steering knuckle behind the brake rotor. The sensor head sits adjacent to the reluctor ring on the hub bearing. On the EDV 500, the sensor is positioned at approximately the 6 o'clock position on the knuckle.
3. 3

   Disconnect sensor electrical connector
   Follow the sensor wire harness up toward the frame rail. Locate the electrical connector approximately 12 inches from the sensor. Depress the locking tab and carefully disconnect the connector. Inspect connector terminals for corrosion or damage.
4. 4

   Release wire harness clips
   The sensor wire harness is secured to the knuckle and suspension components with plastic retaining clips. Carefully release each clip by prying with a small flat blade screwdriver. Note the exact routing of the wire harness for reinstallation.
5. 5

   Remove sensor mounting bolt
   Using a 10mm socket, carefully remove the single bolt securing the wheel speed sensor to the steering knuckle. Do not use power tools. If the bolt is corroded or seized, apply penetrating oil and allow to soak for 10 minutes before removal.
6. 6

   Extract sensor from knuckle
   Gently pull the sensor straight out from the knuckle bore. If the sensor is stuck due to corrosion, carefully twist while pulling. Do not pry against the sensor body or use excessive force. If severely corroded, apply heat to the knuckle (not the sensor) using a heat gun at low setting.
7. 7

   Clean sensor bore and inspect reluctor ring
   Use a wire brush to thoroughly clean the sensor mounting bore in the knuckle, removing all corrosion and debris. Spray electrical contact cleaner into the bore and wipe clean. Inspect the reluctor ring on the hub bearing for damage, missing teeth, or excessive runout. Replace hub bearing if reluctor ring is damaged.
8. 8

   Prepare new sensor for installation
   Remove the new sensor from packaging. Inspect the sensor tip for any metal debris and clean if necessary. Apply a thin coat of anti-seize compound to the sensor body (not the tip). Apply dielectric grease to the electrical connector terminals.
9. 9

   Install new sensor
   Carefully insert the new sensor into the knuckle bore, ensuring it seats fully. The sensor tip should sit approximately 0.5-1.0mm from the reluctor ring teeth. Install the mounting bolt and hand-tighten. Since no torque specification is provided, tighten the bolt firmly to approximately 8-10 ft-lbs, being careful not to over-tighten and strip the aluminum knuckle threads.
10. 10

    Route and secure wire harness
    Route the sensor wire harness following the original path noted during removal. Ensure the harness has adequate slack and will not be stretched during suspension travel or steering movement. Secure all retaining clips firmly. Verify harness does not contact any moving parts, sharp edges, or heat sources.
11. 11

    Connect electrical connector
    Connect the sensor electrical connector, ensuring it clicks firmly into place and the locking tab engages. Gently tug on the connection to verify it is secure.
12. 12

    Reinstall wheel
    Reinstall the wheel and hand-tighten all lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground. Torque lug nuts to manufacturer specification (typically 130-150 ft-lbs for the EDV 500) in a star pattern. Fully lower vehicle and remove jack stands.
13. 13

    Clear codes and perform system test
    Connect the diagnostic scan tool. Clear all ABS fault codes. Perform a wheel speed sensor test using the scan tool to verify the new sensor is reading properly. Start the vehicle and verify the ABS warning light extinguishes after a few seconds.
14. 14

    Perform road test verification
    Drive the vehicle at speeds above 15 mph to allow the ABS module to verify all wheel speed sensors are functioning. Perform several gentle stops to ensure proper ABS operation. Monitor the scan tool for any new fault codes. Verify all four wheel speeds display correctly and match each other during straight-line driving.

Reassembly

1. Reinstall components in reverse order of removal
2. Ensure wire harness routing matches original configuration with no interference points
3. Verify all electrical connections are secure and properly locked
4. Double-check that wheel lug nuts are torqued to specification after test drive

Verification

• ABS warning light should extinguish within 3-5 seconds of starting the vehicle
• Using scan tool, verify the repaired wheel speed sensor shows active signal and matches speed of opposite side wheel during test drive
• No ABS fault codes should be present after clearing codes and completing test drive
• All four wheel speeds should read within 2-3 mph of each other at steady speeds above 25 mph
• ABS system should function normally during gentle brake application on safe surface

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