This procedure covers the removal and replacement of the rear control arm bushings on a 2024 Rivian EDV 500, requiring partial suspension disassembly and specialized pressing tools.

Warnings

Tools required

Parts

• Rear control arm bushing kit (inner and outer) × 2 — Use OEM specification
• Control arm hardware kit (if reuse not recommended) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks at front wheels
3. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
4. Raise vehicle on lift or using jack stands at designated lift points, ensuring adequate working height
5. Remove rear wheels completely
6. Spray all suspension fasteners with penetrating lubricant and allow to soak for 15 minutes
7. Visually inspect which control arm bushing requires replacement (upper or lower, inner or outer)
8. Take reference photos of suspension geometry and fastener locations

Procedure

1. 1

   Support the rear suspension
   Position a transmission jack or adjustable jack stand under the rear knuckle/hub assembly to support the suspension at ride height. This prevents the suspension from dropping and damaging brake lines or ABS sensors when the control arm is disconnected. Adjust support to keep suspension at approximately normal ride height.
2. 2

   Disconnect control arm outer mounting point
   Locate the outer control arm mounting point at the knuckle or hub carrier. Remove the outer control arm bolt and nut using appropriate sockets. Note the orientation of any washers, spacers, or eccentric alignment components for reassembly. If bolt is seized, apply additional penetrating lubricant and use breaker bar.
3. 3

   Disconnect control arm inner mounting point
   Locate the inner control arm mounting point at the subframe or chassis bracket. Remove the through-bolt and nut securing the control arm to the chassis. This bolt typically passes through the bushing being replaced. Support the control arm as you remove the final fastener to prevent it from dropping.
4. 4

   Remove control arm from vehicle
   Carefully lower and remove the control arm from the vehicle. Inspect the mounting points on both the knuckle and chassis for damage, corrosion, or elongated holes. Clean mounting surfaces with wire brush if necessary. Inspect the removed control arm for cracks, bends, or other damage beyond bushing wear.
5. 5

   Press out old bushing
   Secure the control arm in a vise or press fixture. Using the bushing press kit or hydraulic press with appropriate adapters, press the old bushing out of the control arm. Apply pressure evenly and ensure the receiving cup is properly sized to accept the bushing outer shell. If bushing is bonded rubber type, the outer shell may remain and require separate removal.
6. 6

   Clean bushing bore
   Thoroughly clean the bushing bore in the control arm using a wire brush and solvent. Remove all rust, rubber residue, and debris. Inspect the bore for cracks or damage. The bore must be clean and smooth for proper bushing installation. Minor surface rust can be cleaned; deep corrosion may require control arm replacement.
7. 7

   Prepare new bushing for installation
   Remove the new bushing from packaging and verify it matches the original design (check orientation of voids if directional). Apply a thin layer of bushing installation lubricant or soapy water to the outer diameter of the new bushing and the control arm bore. Do not use petroleum-based lubricants on rubber bushings.
8. 8

   Press in new bushing
   Position the new bushing at the control arm bore in the correct orientation (align any voids or flats per manufacturer design). Using the bushing press with properly sized adapters, press the bushing evenly into the bore until it is fully seated and flush with the control arm surface. Ensure the bushing is not cocked or misaligned during pressing.
9. 9

   Reinstall control arm to chassis
   Raise the control arm into position and align the inner mounting point with the chassis bracket. Insert the inner through-bolt and start the nut by hand. Do not fully tighten at this stage - leave fasteners finger-tight to allow suspension geometry adjustment. Ensure any alignment marks or eccentric washers are positioned as noted during disassembly.
10. 10

    Reconnect control arm outer mounting point
    Raise or lower the transmission jack supporting the knuckle to align the control arm outer mounting point. Install the outer bolt, washers, and nut in the correct orientation as documented during removal. Thread nut by hand initially, then snug but do not torque yet.
11. 11

    Load suspension to ride height
    Adjust the transmission jack or support to position the suspension at normal ride height (simulate vehicle weight on wheels). This is critical because control arm bushings must be torqued at ride height to prevent preloading and premature failure. Use a second person or additional supports if needed to maintain this position.
12. 12

    Torque all control arm fasteners
    With suspension at ride height, torque the inner control arm bolt/nut to specification, followed by the outer mounting bolt/nut. Without manufacturer torque specifications available, consult Rivian service information or use equivalent specifications for commercial electric vans (typically 120-150 ft-lb for main control arm mounting bolts, but verification is essential). Torque in the sequence: inner mount first, then outer mount.
13. 13

    Reinstall wheels and lower vehicle
    Remove the transmission jack or support from under the suspension. Reinstall the rear wheels and thread lug nuts by hand. Lower the vehicle until wheels contact the ground but vehicle weight is not fully on suspension. Torque wheel lug nuts to Rivian specification (typically 150 ft-lb for commercial vehicles, but verify). Fully lower vehicle and remove jack stands.

Reassembly

1. Torque wheel lug nuts in a star pattern to ensure even pressure
2. If both sides were serviced, ensure work was performed symmetrically
3. Pump brake pedal several times to ensure proper brake system function before driving

Verification

• Test drive vehicle at low speed in a safe area and verify no unusual noises, vibrations, or handling issues
• Perform a four-wheel alignment immediately after control arm bushing replacement to ensure proper suspension geometry
• Re-torque all control arm fasteners after 50-100 miles of driving
• Inspect for any fluid leaks around brake or differential components that may have been disturbed
• Verify tire wear patterns after 500 miles to confirm proper alignment

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