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

Warnings

Tools required

Parts

• Front upper control arm bushing × 1 — Use OEM Rivian specification
• Control arm mounting hardware kit (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and secure on jack stands at manufacturer-specified lift points
5. Remove front wheel on side being serviced
6. Spray all control arm mounting bolts and ball joint connections with penetrating oil and allow to soak
7. Take photos of control arm orientation for reference during reassembly

Procedure

1. 1

   Support lower control arm
   Position floor jack under the lower control arm near the ball joint to support the suspension weight. Raise jack until it just contacts the control arm without lifting the vehicle further. This prevents the suspension from dropping when the upper control arm is disconnected.
2. 2

   Disconnect upper ball joint
   Remove the castle nut securing the upper ball joint to the steering knuckle. If equipped with a cotter pin, remove it first. Use a ball joint separator tool to break the taper connection between the ball joint stud and knuckle. Avoid hammering directly on threads.
3. 3

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the frame rail or subframe. Support the control arm with one hand and remove the bolt completely. Note the orientation of any washers or spacers for reassembly.
4. 4

   Remove rear control arm mounting bolt
   Remove the rear mounting bolt that secures the control arm to the frame rail or subframe. The bushing being replaced is typically pressed into the control arm at one or both of these mounting points. Once both bolts are removed, carefully lower and remove the control arm from the vehicle.
5. 5

   Inspect control arm
   Clean the control arm thoroughly with wire brush. Inspect for cracks, bends, or other damage. Check ball joint for excessive play or torn boots. If control arm shows damage beyond the bushing, replacement of the entire control arm is recommended.
6. 6

   Press out old bushing
   Using a control arm bushing press kit or hydraulic press, remove the old bushing from the control arm. Select the appropriate receiver cup that is larger than the bushing outer diameter and a driver that matches the bushing size. Press the bushing out slowly, ensuring the control arm is properly supported to prevent distortion. Note the orientation of the bushing before removal.
7. 7

   Clean bushing bore
   Thoroughly clean the bushing bore in the control arm using a wire brush and solvent. Remove all rust, debris, and old rubber material. Inspect the bore for damage, cracks, or out-of-round conditions. The bore must be clean and smooth for proper bushing installation.
8. 8

   Install new bushing
   Apply a thin film of silicone lubricant to the outer surface of the new bushing and the bore of the control arm. Position the new bushing at the bore opening, ensuring proper orientation (match any alignment marks or voids with the original). Using the bushing press kit, slowly press the bushing into the control arm until it is fully seated and flush with the control arm surface. Do not use excessive force or the control arm may distort.
9. 9

   Reinstall control arm to frame
   Position the control arm back into its mounting location on the frame or subframe. Install the front and rear mounting bolts with washers in their original orientation. Thread bolts by hand first to ensure proper alignment. Do not fully tighten bolts at this time.
10. 10

    Reconnect upper ball joint
    Raise the floor jack under the lower control arm to bring the steering knuckle into position. Insert the upper ball joint stud into the knuckle. Install the castle nut and tighten. Install new cotter pin if equipped. The ball joint connection must be secure with no play.
11. 11

    Torque control arm mounting bolts
    With the vehicle weight now supported by the suspension (jack under lower control arm at ride height position), torque the front and rear control arm mounting bolts to specification. Control arm bushings must be torqued at ride height to prevent premature bushing failure. Refer to Rivian service manual for proper torque values as none are available in this database.
12. 12

    Reinstall wheel and lower vehicle
    Reinstall the front wheel and hand-tighten lug nuts in a star pattern. Lower the vehicle to the ground and remove jack stands. Torque lug nuts to specification in a star pattern (refer to Rivian specifications, typically 140-150 ft-lbs for this vehicle class).

Reassembly

1. Reconnect 12V battery negative terminal
2. Start vehicle and verify no warning lights related to suspension or steering systems
3. All control arm fasteners must be torqued to specification at curb ride height to prevent bushing bind and premature failure
4. Do not attempt to drive vehicle at highway speeds before alignment is performed

Verification

• Perform visual inspection of all mounting points to ensure bolts are fully seated and torqued
• Check that ball joint connection is secure with no play
• Test drive vehicle at low speed in safe area and verify no unusual noises, vibrations, or pulling
• Have vehicle professionally aligned immediately after repair to ensure proper suspension geometry and tire wear characteristics
• After 50-100 miles, re-check torque on all control arm mounting bolts

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