This procedure covers the removal and replacement of the upper ball joint on a 2024 Rivian EDV 500 electric delivery van with dual motor AWD drivetrain.

Warnings

Tools required

Parts

• Upper ball joint × 1 — Use OEM Rivian specification
• Upper ball joint castle nut × 1 — Replace if equipped, Use OEM specification
• Cotter pin × 1 — If equipped with castle nut

Preparation

1. Park vehicle on level, solid ground and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal and wait 5 minutes for system discharge
4. Loosen front wheel lug nuts while vehicle is on ground
5. Raise front of vehicle using proper jack points and support with jack stands rated for vehicle weight
6. Remove front wheel on affected side
7. Spray all ball joint fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove wheel speed sensor if obstructing access
   Locate the front wheel speed sensor mounted near the upper control arm. If it obstructs access to the upper ball joint, disconnect the electrical connector and remove the mounting bolt. Secure sensor away from work area with wire or zip tie to prevent damage.
2. 2

   Support lower control arm
   Position a floor jack under the lower control arm to support the weight of the suspension assembly. Raise jack just enough to take tension off the upper ball joint but not to lift the vehicle. This prevents the suspension from dropping suddenly when the ball joint is disconnected.
3. 3

   Remove brake caliper and secure out of way
   Remove the brake caliper mounting bolts and carefully slide the caliper off the rotor. Do not allow the caliper to hang by the brake hose. Support it with a wire hanger or bungee cord attached to the chassis or suspension component.
4. 4

   Disconnect upper ball joint from steering knuckle
   Remove the cotter pin (if equipped) and loosen the upper ball joint castle nut or retaining nut. Do not remove completely yet. Use a ball joint separator or pickle fork to break the taper between the ball joint stud and the steering knuckle. Once separated, remove the nut completely and extract the ball joint stud from the knuckle.
5. 5

   Remove upper control arm mounting bolts if necessary
   Depending on ball joint design, you may need to unbolt the upper control arm from the frame to access the ball joint. If the ball joint is pressed into the control arm, mark the position of any alignment cams or shims before removal. Remove the control arm bolts and carefully lower the control arm from the vehicle.
6. 6

   Remove old ball joint from control arm
   If the ball joint is pressed into the control arm, use a ball joint press or C-frame press to remove it. Position the press tools to support the control arm from below and press the old ball joint out from above. Apply steady, even pressure. Clean the ball joint bore thoroughly with a wire brush, removing all corrosion and debris.
7. 7

   Inspect control arm and knuckle
   Carefully inspect the control arm ball joint bore for cracks, elongation, or damage. Check the steering knuckle taper for wear, scoring, or damage. Replace any damaged components. Verify the new ball joint fits properly in the control arm bore without excessive play.
8. 8

   Install new ball joint into control arm
   Position the new ball joint in the control arm bore, ensuring it is oriented correctly with grease fittings (if equipped) accessible. Use the ball joint press to install the new joint, pressing it squarely into the bore until fully seated. The ball joint should be flush or slightly below the control arm surface as specified by design.
9. 9

   Reinstall upper control arm if removed
   If the control arm was removed, position it back into the mounting location. Align any shims or alignment cams to their marked positions. Install mounting bolts finger-tight initially. Do not fully torque at this time as suspension must be at ride height for proper torquing.
10. 10

    Connect ball joint stud to steering knuckle
    Insert the upper ball joint stud into the steering knuckle taper. Install the castle nut or retaining nut and tighten to draw the taper together. Without torque specifications available, tighten firmly while ensuring the stud seats completely into the taper. Install a new cotter pin if equipped with castle nut design.
11. 11

    Reinstall brake caliper
    Position the brake caliper over the rotor and install the mounting bolts. Tighten the caliper bolts firmly and evenly. Reconnect any brake wear sensors or ABS wiring that was disconnected.
12. 12

    Reconnect wheel speed sensor
    If the wheel speed sensor was removed, reinstall it in its mounting location and tighten the mounting bolt. Reconnect the electrical connector ensuring it clicks fully into place. Verify the sensor gap is correct and the wiring is secured away from rotating components.
13. 13

    Lower suspension to ride height and torque fasteners
    Remove the floor jack from under the lower control arm. Lower the vehicle until the suspension is at normal ride height (tires just touching ground with full vehicle weight on suspension). At this position, torque the upper control arm mounting bolts if they were removed. Without specific torque values, tighten firmly and evenly, checking manufacturer service information for exact specifications.
14. 14

    Reinstall wheel and lower vehicle
    Install the wheel and thread lug nuts by hand. Lower the vehicle completely to the ground. Torque the wheel lug nuts to specification in a star pattern (typically 140-150 ft-lbs for this vehicle class, verify exact specification).

Reassembly

1. Reconnect 12V battery negative terminal
2. Pump brake pedal several times to restore brake pressure before moving vehicle
3. Check brake fluid level and top off with DOT 4 brake fluid if necessary
4. Test brake operation in a safe area before driving on public roads

Verification

• Start vehicle and verify no warning lights related to ABS or stability control systems
• Perform a visual inspection of all fasteners to ensure nothing was missed
• Test drive vehicle at low speed in a safe area, checking for unusual noises, vibrations, or handling issues
• Schedule immediate wheel alignment as suspension geometry has been altered
• After alignment, verify steering wheel is centered and vehicle tracks straight
• Re-check all fastener torques after 50-100 miles of driving

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