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

Warnings

Tools required

Parts

• Front coil spring (left) × 1 — Use OEM specification
• Front coil spring (right) × 1 — Use OEM specification
• Strut mount bearing/plate hardware kit × 1 — Use OEM specification
• Strut bumper (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Access the high-voltage disconnect (typically under rear cargo area or driver's seat) and follow Rivian's lockout/tagout procedure to de-energize the high-voltage system
4. Wait minimum 5 minutes after HV disconnect for capacitor discharge
5. Use multimeter to verify 0V across HV terminals before proceeding
6. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
7. Raise front of vehicle with floor jack at designated front jacking point
8. Support vehicle on jack stands at front frame rail points rated for vehicle weight
9. Remove front wheels completely
10. Spray all suspension fasteners with penetrating lubricant and allow to soak for 10-15 minutes
11. Take photos of suspension assembly orientation for reference during reassembly

Procedure

1. 1

   Disconnect stabilizer bar end links
   Locate the stabilizer bar end links connecting the sway bar to the strut assemblies. Support the sway bar with a bungee cord or wire to prevent it from hanging. Remove the upper nut connecting each end link to the strut. This allows the strut to drop further for spring access.
2. 2

   Disconnect wheel speed sensor and brake line brackets
   Locate the ABS wheel speed sensor mounted on the steering knuckle. Disconnect the electrical connector and carefully unclip the sensor wire from any routing brackets on the strut. Remove any brake line brackets attached to the strut to allow free movement. Do not disconnect the brake line itself.
   ⚠Do not pull on wheel speed sensor wires with force. These sensors are fragile and expensive to replace.
3. 3

   Separate upper control arm ball joint
   If equipped with upper control arms, locate the upper ball joint connection to the steering knuckle. Remove the castle nut or fastener securing the ball joint. Use a ball joint separator tool to disconnect the upper control arm from the knuckle. If no upper control arm is present, proceed to next step.
4. 4

   Remove strut top mount fasteners
   Open the hood and locate the strut tower in the engine bay. The top mount plate will have 3-4 nuts securing it to the strut tower. Have an assistant support the strut assembly from below, or use a jack under the lower control arm for support. Remove all but one of the top mount nuts, then carefully remove the final nut while controlling the strut assembly.
   ⚠️The strut assembly is heavy and under spring tension. Ensure it is properly supported before removing the last top mount fastener or it may fall.
5. 5

   Disconnect lower strut mounting
   Locate the lower strut mounting bolts connecting the strut to the steering knuckle or lower mount point. These are typically 2 large pinch bolts. Remove these fasteners and carefully separate the strut from the knuckle. You may need to use a pry bar to spread the knuckle clamp. Carefully lower the strut assembly down and maneuver it out from the wheel well.
6. 6

   Install spring compressor on first coil spring
   With the strut assembly removed and placed securely on a workbench, install the coil spring compressor according to the manufacturer's instructions. Position the compressor hooks evenly on opposite sides of the spring, ensuring at least 3-4 coils are engaged. Verify hooks are fully seated in the coil valleys. Alternate tightening the compressor evenly on both sides to compress the spring gradually.
   ⚠️Compress the spring slowly and evenly. Check compressor hook engagement after every few turns. An improperly secured compressor can allow the spring to release violently.
7. 7

   Remove strut shaft nut and top mount
   Once the spring is compressed enough that the top mount is no longer under pressure (you should be able to wiggle it slightly), hold the strut shaft with a wrench or hex socket to prevent rotation. Remove the top shaft nut. Carefully remove the top mount plate, bearing assembly, and upper spring seat. Note the exact orientation and order of all components for reassembly.
8. 8

   Remove compressed spring and spring seats
   With the top mount removed, carefully lift the compressed spring off the strut. Keep the compressor installed and set aside safely. Remove the lower spring seat/isolator from the strut body. Inspect the strut bumper for damage and replace if torn or compressed. Clean all mounting surfaces on the strut body.
9. 9

   Install new spring with compressor
   Install the spring compressor on the new coil spring using the same technique as removal. Compress the new spring to approximately the same compressed length as the old spring. Install the lower spring seat/isolator on the strut body in the correct orientation. Carefully lower the compressed new spring onto the strut, aligning the spring end with the step/locator on the lower spring seat.
   ⚠New springs may have a protective coating. This is normal and will wear during initial use.
10. 10

    Install top mount and strut shaft nut
    Place the upper spring seat on top of the spring in the correct orientation (note the alignment of the spring end to the seat). Install the bearing assembly and top mount plate in the exact order and orientation documented during disassembly. Install the strut shaft nut and tighten while holding the shaft to prevent rotation. Without factory torque specifications, tighten to secure the assembly but do not over-torque (consult Rivian service information).
11. 11

    Release spring compressor
    Very carefully and gradually loosen the spring compressor, alternating evenly between both sides. As you release tension, verify the spring is properly seating in both upper and lower spring seats. Once all tension is transferred to the strut assembly and the spring is fully seated, remove the compressor completely.
    ⚠️If the spring begins to misalign or pop out of the seats during release, immediately stop and re-compress to correct the alignment.
12. 12

    Reinstall strut assembly in vehicle
    Carefully maneuver the strut assembly back into the wheel well. Align the lower strut mounting with the steering knuckle and install the pinch bolts finger-tight. Guide the strut shaft through the top mount hole in the strut tower. Install the top mount nuts and tighten in a star pattern. Then torque all top mount fasteners per Rivian specifications (consult factory service manual).
13. 13

    Reconnect suspension components
    Torque the lower strut pinch bolts per Rivian specifications. Reconnect the upper control arm ball joint if applicable and torque fasteners. Reconnect the stabilizer bar end links and torque per specifications. Reattach all brake line brackets and wheel speed sensor wiring to their original routing positions. Reconnect the wheel speed sensor connector.
14. 14

    Repeat for opposite side
    Perform steps 1-13 for the opposite front coil spring. Ensure both sides are assembled identically with all components properly oriented and fasteners torqued to specification.
15. 15

    Reinstall wheels and perform final checks
    Reinstall both front wheels and tighten lug nuts in a star pattern. Lower the vehicle to the ground and torque lug nuts to Rivian specification (typically 140-150 ft-lb for commercial vehicles, verify exact specification). Re-enable the high-voltage system following Rivian's reconnection procedure. Start the vehicle and verify no warning lights appear on the dash.

Reassembly

1. All suspension fasteners must be torqued to Rivian factory specifications. Without these values documented here, you must obtain official service information before final assembly.
2. Suspension fasteners should be torqued with the vehicle at normal ride height (on the ground) for proper preload on rubber bushings where applicable.
3. Verify all brake line brackets are securely reattached and brake lines have no tension or binding through full steering lock.
4. Check that wheel speed sensor wiring has adequate slack and will not be pinched or pulled during suspension travel.

Verification

• With vehicle on level ground, visually verify both front corners are at equal height with no sagging.
• Bounce each front corner of the vehicle and verify the suspension rebounds smoothly without squeaking or binding.
• Turn steering wheel full lock in both directions and verify no contact or interference between suspension components and wheels.
• Test drive the vehicle at low speed in a safe area and verify normal handling with no pulling, wandering, or unusual noises.
• Check for any warning lights on the instrument cluster, particularly ABS or suspension-related warnings.
• Have the vehicle's wheel alignment checked and adjusted by a professional within 24 hours of completing this repair. Improper alignment will cause premature tire wear.
• After 50-100 miles of driving, re-torque all suspension fasteners to verify no loosening has occurred.

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