This procedure covers the removal and replacement of upper and lower ball joints on the front suspension of a 2024 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Upper ball joint (front, left) × 1 — Use OEM specification
• Upper ball joint (front, right) × 1 — Use OEM specification
• Lower ball joint (front, left) × 1 — Use OEM specification
• Lower ball joint (front, right) × 1 — Use OEM specification
• Castle nut for ball joint stud × 4 — Use OEM specification
• Cotter pins × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise vehicle on lift or jack and support with jack stands at designated frame lift points
5. Remove front wheels and set aside
6. Spray ball joint stud nuts and control arm fasteners with penetrating oil and allow to soak for 15 minutes
7. Inspect suspension for additional worn components that may need replacement

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the suspension load. Raise jack just enough to take the weight off the ball joint but not lift the vehicle. This prevents the suspension from dropping when the ball joint is separated.
2. 2

   Remove upper ball joint castle nut
   Remove the cotter pin from the upper ball joint castle nut using pliers or side cutters. Using a socket and breaker bar, remove the castle nut from the upper ball joint stud. Do not fully remove if the stud is under tension - keep a few threads engaged until the joint is separated.
3. 3

   Separate upper ball joint from knuckle
   Insert a ball joint separator tool between the steering knuckle and upper control arm. Strike the separator with a hammer to break the taper fit between the ball joint stud and knuckle. Alternatively, use a pickle fork tool, being aware this may damage the ball joint boot. Once separated, remove the castle nut completely and guide the stud out of the knuckle.
4. 4

   Remove upper control arm fasteners
   Locate the fasteners securing the upper control arm to the frame. Remove the bolts or nuts attaching the control arm (typically at the front and rear pivot points). Support the control arm as you remove the final fastener. Lower the control arm assembly and move it away from the work area or let it hang if equipped with adjustable links.
5. 5

   Press out upper ball joint
   With the control arm removed, clean the ball joint housing bore with a wire brush. Position the control arm in a ball joint press or use a bench-mounted press. Select the appropriate press adapters for the upper ball joint size. Press the old ball joint out of the control arm, applying steady pressure. Ensure the press is aligned to prevent damage to the control arm bore.
6. 6

   Install new upper ball joint
   Clean the control arm bore thoroughly and inspect for damage or distortion. Position the new upper ball joint in the control arm bore, noting the correct orientation (stud direction). Using the ball joint press with proper adapters, press the new ball joint into the control arm until it is fully seated and flush with the control arm surface. Ensure even pressure during installation to prevent cocking.
7. 7

   Remove lower ball joint castle nut
   Remove the cotter pin from the lower ball joint castle nut. Loosen and remove the castle nut from the lower ball joint stud. If the stud spins, use a 6-point socket on the stud end while turning the nut, or use a ball joint stud wrench to hold the stud.
8. 8

   Separate lower ball joint from knuckle
   Using a ball joint separator or pickle fork, separate the lower ball joint stud from the steering knuckle. Position the tool correctly to avoid damaging the knuckle or CV boot. Strike the separator firmly until the taper breaks free. The steering knuckle can now pivot away from the lower control arm. Support the knuckle and hub assembly to prevent stress on the CV axle and brake lines.
9. 9

   Remove lower ball joint from control arm
   Identify how the lower ball joint is secured to the lower control arm. If bolted, remove the mounting bolts. If pressed, use a ball joint press to remove it following the same procedure as the upper ball joint. For riveted ball joints, drill out the rivets using the specified drill bit size, then chisel off rivet heads and punch out rivet bodies. Clean the mounting surface thoroughly after removal.
10. 10

    Install new lower ball joint
    Position the new lower ball joint in the lower control arm. If the design uses a press-fit, press the ball joint into place using the ball joint press with correct adapters until fully seated. If bolted, align the ball joint and install new bolts with thread locker, tightening in a cross pattern. For replacements of riveted joints, use the supplied bolts and nuts, applying thread locker and tightening securely.
11. 11

    Reconnect lower ball joint to knuckle
    Guide the lower ball joint stud through the hole in the steering knuckle. Install a new castle nut on the lower ball joint stud. Tighten the castle nut to the specified torque (specification required from factory manual). Align the castle nut slots with the hole in the ball joint stud and install a new cotter pin. Bend the cotter pin ends to secure.
12. 12

    Reinstall upper control arm and ball joint
    Position the upper control arm back into its mounting location on the frame. Install the pivot bolts or fasteners and tighten finger-tight. Guide the upper ball joint stud into the steering knuckle hole. Install a new castle nut on the upper ball joint stud and tighten to specification. Align castle nut slots with stud hole and install new cotter pin. Tighten upper control arm pivot fasteners to specification with suspension at ride height.
13. 13

    Torque all fasteners to specification
    With the jack still supporting the lower control arm at ride height position, torque all suspension fasteners to factory specifications. This includes upper control arm pivot bolts, lower ball joint bolts (if applicable), and both castle nuts. Note that many suspension fasteners must be torqued at ride height to prevent bushing preload issues. Castle nuts should be tightened to specification, then advanced only enough to align the slot with the cotter pin hole.
14. 14

    Repeat for opposite side
    Lower the jack from under the control arm and repeat steps 1 through 13 for the opposite side of the vehicle. Maintain the same installation procedures and cleanliness standards.

Reassembly

1. Remove jack stands and lower the floor jack slowly while guiding suspension components
2. Install front wheels and tighten lug nuts in a star pattern to specification
3. Lower vehicle to ground and perform final wheel lug nut torque
4. Reconnect 12V auxiliary battery negative terminal
5. Bounce each corner of the vehicle several times to settle the suspension

Verification

• Perform a visual inspection of all ball joint installations to ensure proper seating and cotter pin installation
• Check that all fasteners are torqued to specification and properly secured
• With vehicle on ground, check for any abnormal suspension position or stance
• Test drive vehicle at low speed in a safe area, listening for any clunks, pops, or abnormal noises
• Verify steering returns to center properly and there is no binding
• Schedule a professional alignment immediately after completing this repair, as ball joint replacement affects alignment settings
• Re-inspect all fasteners after 50-100 miles of driving

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