This procedure covers the removal and replacement of the front coil springs on a 2024 Rivian EDV 500 electric delivery van, requiring suspension disassembly and the use of a spring compressor.

Warnings

Tools required

Parts

• Front coil spring × 1 — Use OEM Rivian specification for EDV 500
• Upper strut mount (if worn) × 1 — Inspect during disassembly
• Lower spring isolator/seat (if damaged) × 1 — Inspect during disassembly
• Upper spring isolator (if damaged) × 1 — Inspect during disassembly

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Chock rear wheels securely on both sides
3. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes to allow systems to power down
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Lift front of vehicle using manufacturer-recommended lift points and support on jack stands rated for full vehicle weight
6. Remove front wheel and tire assembly on side being serviced
7. Spray all suspension fasteners with penetrating oil and allow to soak for 15 minutes
8. Take photos of suspension assembly orientation for reference during reassembly
9. Verify you have obtained factory torque specifications from Rivian service information before proceeding

Procedure

1. 1

   Support lower control arm
   Position a hydraulic floor jack under the lower control arm as close to the ball joint as possible. Raise jack just enough to support the weight of the control arm and relieve tension on the shock absorber. Do not lift the vehicle. The jack will control the descent of the control arm during disassembly and prevent sudden release of spring tension.
2. 2

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor connector near the strut assembly. Depress the locking tab and disconnect the electrical connector. Unclip the sensor wire from any retaining clips on the strut or control arm to prevent damage during disassembly. Secure the sensor wire away from the work area.
3. 3

   Remove brake caliper and secure
   Remove the brake caliper mounting bolts and carefully lift the caliper off the rotor. Do NOT let the caliper hang by the brake hose. Use wire or a bungee cord to suspend the caliper from the chassis or upper control arm. Remove the brake rotor if it interferes with access to suspension components.
4. 4

   Disconnect outer tie rod end
   Remove the cotter pin and castle nut from the outer tie rod end ball joint. Use a ball joint separator or pickle fork to disconnect the tie rod end from the steering knuckle. Count and record the number of threads visible on the tie rod for approximate reassembly position.
5. 5

   Disconnect lower ball joint
   Remove the lower ball joint pinch bolt or castle nut (depending on EDV 500 design). Use a ball joint separator to disconnect the lower control arm from the steering knuckle. If using a pickle fork, be aware this may damage the ball joint boot. Once separated, support the steering knuckle to prevent it from falling or putting strain on the CV axle.
6. 6

   Remove upper strut mounting nuts
   Access the upper strut mount nuts from under the hood by removing any covers or panels over the strut tower. Have an assistant support the strut assembly from below, or use a second jack. Remove the upper strut mount nuts (typically 3 or 4 nuts). Do NOT remove the large center nut on the strut shaft at this time.
7. 7

   Remove strut assembly
   Carefully lower the hydraulic jack supporting the lower control arm to release tension. Guide the strut assembly down and out of the wheel well. The spring is still under compression between the strut and control arm seats. Place the strut assembly on a stable workbench.
8. 8

   Install spring compressor
   Install a coil spring compressor tool according to the manufacturer's instructions. Ensure the compressor hooks are properly seated in the spring coils and are positioned opposite each other for balanced compression. The compressor must be rated for the spring load of this commercial vehicle. Begin compressing the spring evenly, alternating between compression points to maintain even pressure.
   ⚠️Compress the spring slowly and evenly. Check frequently that the compressor hooks remain properly seated. An improperly compressed spring can release violently and cause fatal injuries.
9. 9

   Remove strut shaft nut
   Once the spring is sufficiently compressed that the upper strut mount is loose and can rotate freely, secure the strut shaft from rotating (typically with an Allen key or double-nut method). Remove the large nut on top of the strut shaft. Carefully remove the upper strut mount, bearing plate, and upper spring seat/isolator. Keep all components in order for reassembly.
10. 10

    Remove compressed spring
    Carefully slide the compressed coil spring off the strut shaft. Keep the spring compressor installed and under tension. Inspect the spring for cracks, corrosion, or damage. Inspect the upper and lower spring isolators/seats for wear, cracking, or compression damage. Replace any worn components.
11. 11

    Install new spring on strut
    Install the new coil spring with the spring compressor already attached and compressed to approximately the same length as the old spring. Ensure any orientation marks or end configurations match the original spring position. The spring end must seat properly in the lower spring seat on the strut body. Install the upper spring isolator/seat over the top of the spring.
12. 12

    Reassemble strut components
    Install the bearing plate and upper strut mount in the correct orientation (refer to photos taken during disassembly). Thread the strut shaft nut onto the shaft and tighten while holding the shaft from rotating. Tighten the shaft nut to factory specification (obtain from Rivian service information). Once the nut is properly torqued, carefully and evenly release the spring compressor tension, ensuring the spring seats properly in both upper and lower seats.
    ⚠️As you release the spring compressor, watch carefully that the spring remains properly seated. If the spring begins to shift or pop out of position, immediately stop and re-compress to correct the alignment.
13. 13

    Install strut assembly
    Lift the strut assembly into position in the wheel well. Align the upper strut mount studs with the holes in the strut tower. Install the upper mount nuts and tighten to factory specification. Use the hydraulic jack to raise the lower control arm up to meet the steering knuckle and ball joint.
14. 14

    Reconnect suspension components
    Reconnect the lower ball joint to the steering knuckle and install the pinch bolt or castle nut. Tighten to factory specification. Reconnect the outer tie rod end to the steering knuckle, tighten the castle nut to specification, and install a new cotter pin. Reinstall the brake rotor and caliper, torquing caliper mounting bolts to specification. Reconnect the ABS sensor connector and secure wiring to clips.
15. 15

    Final assembly and load settling
    Reinstall the wheel and tire, hand-tightening lug nuts. Lower the vehicle to the ground and torque lug nuts to factory specification in a star pattern. Reconnect the 12V battery. Bounce the front end of the vehicle several times to settle the suspension before final inspection. Repeat entire procedure for opposite side if replacing both springs.

Reassembly

1. All fasteners must be torqued to Rivian factory specifications using a calibrated torque wrench
2. New cotter pins must be used on all castle nuts - never reuse old cotter pins
3. Ensure all electrical connectors are fully seated and locked
4. Verify brake caliper mounting bolts are properly torqued and calipers operate freely

Verification

• Perform a visual inspection of all suspension connections to ensure proper assembly and that no tools or parts were left in the wheel well
• Test drive the vehicle at low speed in a safe area and verify no unusual noises, vibrations, or steering pull
• Check that ABS warning light does not illuminate, confirming wheel speed sensor is properly connected
• MANDATORY: Schedule four-wheel alignment at a facility with commercial vehicle alignment equipment immediately after repair
• After 50-100 miles of driving, re-torque all suspension fasteners and wheel lug nuts to specification
• Inspect for any signs of unusual tire wear or suspension component movement after the first 500 miles

More procedures for this vehicle