This procedure covers the removal and replacement of the front lower control arm bushings on a 2024 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Front lower control arm bushing kit × 2 — Use OEM specification
• Control arm mounting bolts (if corroded) × 4 — Use OEM specification
• Ball joint castle nut (if equipped) × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect the 12V auxiliary battery negative terminal and wait 2 minutes
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Raise front of vehicle using approved lift points per Rivian service manual
6. Support vehicle securely on jack stands at designated frame points
7. Remove front wheels completely
8. Spray all control arm fasteners with penetrating lubricant and allow to soak
9. Take photos of control arm orientation and routing of any nearby wiring or brake lines

Procedure

1. 1

   Access and support the front suspension
   Position a hydraulic jack under the lower control arm near the ball joint to support the suspension weight. Raise jack just enough to take the load but not lift the vehicle. This keeps the suspension geometry neutral and prevents sudden movement when fasteners are removed.
2. 2

   Disconnect ABS/wheel speed sensor wiring
   Locate the wheel speed sensor wire attached to or near the lower control arm. Disconnect the electrical connector and carefully release any clips or routing brackets that attach the wire to the control arm. Use zip ties or safety wire to secure the harness away from the work area.
3. 3

   Remove the lower ball joint connection
   Remove the castle nut or pinch bolt connecting the lower ball joint to the steering knuckle. If using a castle nut, remove the cotter pin first. Use a ball joint separator or pickle fork to break the taper connection between the ball joint stud and knuckle. Support the knuckle to prevent strain on the CV axle once separated.
   ⚠Do not strike the ball joint stud directly with a hammer as this can damage the joint. Use proper separation tools.
4. 4

   Disconnect sway bar end link
   Locate the sway bar end link connection to the lower control arm. Use a wrench to hold the ball joint stud while removing the retaining nut with another wrench. Disconnect the end link from the control arm and secure it out of the way with wire or zip ties.
5. 5

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the subframe or chassis. This bolt passes through the bushing you will be replacing. Use a breaker bar to loosen and remove this bolt completely. Support the control arm as you remove the bolt to prevent it from dropping.
6. 6

   Remove front control arm mounting bolt
   Locate and remove the front mounting bolt that secures the control arm to the subframe. This bolt also passes through a bushing. Once removed, carefully lower the hydraulic jack to allow the control arm to drop free from the vehicle. Remove the control arm completely and place on a clean work surface.
7. 7

   Inspect control arm and prepare for bushing removal
   Clean the control arm thoroughly with a wire brush. Inspect the arm for cracks, bends, or other damage. If damage is found, the entire control arm must be replaced rather than just the bushings. Mark the orientation of the old bushings before removal if they have directional installation.
8. 8

   Press out old bushings
   Using a hydraulic press or control arm bushing press kit, carefully press the old bushings out of the control arm. Select the appropriate adapter cups from your press kit that match the bushing diameter. Apply steady, even pressure to avoid damaging the control arm bore. Press from the side that provides the straightest path for bushing removal.
   ⚠Ensure the control arm is properly supported and aligned in the press to prevent arm damage or personal injury from slipping.
9. 9

   Clean bushing bores
   After removing old bushings, thoroughly clean the bushing bores in the control arm using a wire brush and clean shop towels. Remove all rust, old rubber material, and debris. Inspect the bores for damage, scoring, or excessive wear. The bore should be smooth and round for proper new bushing installation.
10. 10

    Install new bushings
    Apply a thin film of dish soap or dedicated bushing lubricant to the outer sleeve of the new bushings and the control arm bores. Position the new bushing at the control arm bore opening, ensuring correct orientation per manufacturer markings. Using the hydraulic press with appropriate adapters, press the new bushing into place until it is fully seated and flush with the control arm. The bushing should be centered in the bore with equal amounts visible on both sides if it is a through-bore design.
    ℹ️Do not use petroleum-based lubricants as they can degrade rubber bushings. Use only soap, water, or specified bushing lubricants.
11. 11

    Reinstall control arm to vehicle
    Position the control arm back into the mounting locations on the subframe. Insert the front mounting bolt first, threading it by hand but not tightening. Then insert the rear mounting bolt and thread by hand. Use the hydraulic jack to raise the outer end of the control arm to align with the steering knuckle ball joint location.
12. 12

    Reconnect ball joint and sway bar
    Reconnect the lower ball joint to the steering knuckle. Install the castle nut or pinch bolt and tighten to proper specification. Install a new cotter pin if applicable. Reconnect the sway bar end link to the control arm and install the retaining nut, holding the ball stud with a wrench while tightening.
13. 13

    Torque all control arm fasteners
    With the vehicle weight on the jack stands and the suspension at normal ride height (jack supporting the control arm at proper position), torque all control arm mounting bolts to Rivian specifications. Torque the ball joint fasteners and sway bar end link nuts to specification. All suspension fasteners must be torqued with the suspension at ride height to prevent bushing pre-load and premature wear.
    ℹ️Suspension bushings must be torqued at ride height, not with suspension hanging free. Failure to do so will cause premature bushing failure.
14. 14

    Reconnect wiring and repeat for opposite side
    Reconnect the wheel speed sensor wiring and secure all clips and routing brackets. Ensure no wiring is pinched or in contact with moving suspension components. Remove the jack from under the control arm. Repeat the entire procedure for the opposite side front control arm.

Reassembly

1. Reinstall front wheels and hand-tighten lug nuts in a star pattern
2. Carefully raise vehicle to remove jack stands
3. Lower vehicle completely to ground
4. Torque wheel lug nuts to specification in a star pattern
5. Reconnect the 12V auxiliary battery negative terminal
6. Remove wheel chocks

Verification

• Start the vehicle and verify no warning lights are present on the dashboard
• Verify wheel speed sensor functionality through the vehicle diagnostic system if available
• Perform a test drive at low speed in a safe area, checking for unusual noises, vibrations, or handling issues
• Inspect all fasteners after test drive to ensure none have loosened
• Schedule a professional alignment as control arm bushing replacement affects suspension geometry
• Re-torque all control arm fasteners after 100 miles of driving

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