This procedure covers the removal and replacement of both front strut assemblies on the 2024 Rivian EDV 500 electric delivery van, including suspension disconnection and wheel alignment requirements.

Warnings

Tools required

Parts

• Front strut assembly - left × 1 — Use OEM specification
• Front strut assembly - right × 1 — Use OEM specification
• Strut upper mount nuts (if corroded) × 6 — M12 x 1.5 flange nuts
• Lower control arm pinch bolt × 2 — Use OEM specification
• Sway bar link nuts × 2 — Use OEM specification
• Anti-seize compound × 1 — Copper-based

Preparation

1. Park vehicle on level, solid ground. Apply parking brake and chock rear wheels securely.
2. Disconnect 12V low-voltage battery negative terminal and wait 5 minutes for system capacitors to discharge.
3. Mark the relationship between upper strut mount and strut tower with paint marker for reference positioning.
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove).
5. Raise front of vehicle using floor jack at manufacturer-specified front jacking point.
6. Place jack stands under frame rails at designated support points on both sides.
7. Remove both front wheels completely and set aside.
8. Spray all suspension fasteners with penetrating oil and allow to soak for 10-15 minutes.
9. Photograph suspension assembly from multiple angles for reassembly reference.

Procedure

1. 1

   Access upper strut mount
   Open front hood. Locate the strut tower in the engine bay behind the front motor assembly. Remove any plastic covers or wiring harness clips that obstruct access to the three upper strut mount nuts. On this electric vehicle, there may be high-voltage cable routing nearby - identify and note orange cables but do not disturb them.
2. 2

   Support lower control arm
   Position floor jack under the lower control arm near the ball joint to support the weight of the suspension. Raise jack until it just contacts the control arm with slight upward pressure. This relieves tension on the strut and prevents suspension from dropping when disconnected.
3. 3

   Disconnect brake line bracket and ABS sensor
   Locate the brake line bracket attached to the strut body. Remove the mounting bolt and carefully reposition the brake line away from the strut without kinking or straining. If equipped, disconnect the ABS wheel speed sensor connector and remove any sensor wire clips from the strut. Secure wiring away from work area with wire or zip ties.
4. 4

   Disconnect sway bar link
   Locate the sway bar end link connecting the stabilizer bar to the strut. Use a wrench to hold the stud while removing the upper nut with another wrench. If the stud spins, use a ball joint separator or allow the nut to spin off while holding the link. Remove the end link from the strut mounting point.
5. 5

   Remove lower strut-to-knuckle pinch bolt
   Locate the large pinch bolt that clamps the strut shaft into the steering knuckle. This is typically at the bottom of the strut where it inserts into a split collar on the knuckle. Remove the pinch bolt completely. You may need to use a pry bar to spread the knuckle collar slightly to release the strut. Mark the strut orientation relative to the knuckle before separation.
6. 6

   Remove upper strut mount nuts
   From under the hood, remove the three nuts securing the upper strut mount to the strut tower. Have an assistant support the strut from below, or ensure the floor jack under the control arm is preventing the suspension from dropping. Remove all three nuts but do not allow the strut to fall.
7. 7

   Remove strut assembly
   Carefully lower the floor jack supporting the control arm while guiding the strut assembly out of the knuckle and down through the fender well. You may need to rotate or angle the strut to clear brake components and wheel well. Once free, remove the complete strut assembly from the vehicle and place on a clean work surface.
8. 8

   Install spring compressor on old strut (if transferring components)
   If you are transferring the spring, upper mount, or other components to the new strut, install spring compressors on opposite sides of the coil spring (180 degrees apart). Tighten compressors evenly and gradually, alternating between sides, until spring tension is fully relieved from the upper mount. The upper mount should be loose and able to rotate freely when adequate compression is achieved.
   ⚠️Spring compressors must be installed correctly per tool manufacturer instructions. Ensure hooks are fully engaged on spring coils. Failure to properly compress spring can result in violent spring release.
9. 9

   Prepare new strut assembly
   If new struts come as complete assemblies with springs and mounts, inspect for shipping damage and verify correct part numbers for left and right sides. If transferring components, compress the new strut spring, install upper mount in the same orientation as marked on the original, and release spring compressors gradually. Clean all mounting surfaces with wire brush and apply anti-seize to threads.
10. 10

    Install new strut into vehicle
    Position the new strut assembly into the wheel well. Guide the upper mount studs through the strut tower holes, ensuring proper alignment with the reference marks made during disassembly. Have an assistant support the strut or use the floor jack under the control arm to raise the suspension as needed. Thread the three upper mount nuts onto the studs by hand.
11. 11

    Connect lower strut to knuckle
    Raise the floor jack under the control arm to align the strut shaft with the knuckle collar. Insert the strut shaft into the knuckle, ensuring the orientation matches the reference marks. You may need to spread the knuckle collar slightly with a pry bar. Install the pinch bolt and thread the nut by hand. Note: Do not fully torque fasteners yet.
12. 12

    Reconnect sway bar link and accessories
    Reconnect the sway bar end link to the strut mounting point and install the nut. Reattach the brake line bracket to the strut body and secure with the mounting bolt. Reconnect the ABS wheel speed sensor connector if equipped, and reinstall all sensor wire clips along the strut. Ensure no wires or hoses are pinched or strained.
13. 13

    Torque all fasteners
    WITH VEHICLE WEIGHT ON SUSPENSION (lower vehicle onto jack stands or wheels): Torque all fasteners to manufacturer specifications in this order: upper strut mount nuts, lower strut pinch bolt, sway bar link nut, brake line bracket bolt. CRITICAL: Without official Rivian torque specifications, this step cannot be completed safely. You must obtain these values from Rivian service documentation before proceeding.
    ⚠️Suspension fasteners MUST be torqued with vehicle weight on suspension (at ride height). Torquing with suspension hanging can cause bushing bind and premature failure.
    ℹ️This procedure cannot proceed without manufacturer torque specifications. Under-torquing can cause fastener loosening and component separation. Over-torquing can cause fastener failure.
14. 14

    Repeat for opposite side
    Perform steps 2 through 13 for the opposite front strut. Ensure both sides are completed identically with all fasteners properly torqued.
15. 15

    Install wheels and lower vehicle
    Reinstall both front wheels, threading lug nuts by hand. Carefully raise vehicle with floor jack, remove jack stands, and lower vehicle to ground. Torque wheel lug nuts to specification in a star pattern. Reconnect the 12V battery negative terminal.

Reassembly

1. All suspension fasteners must be torqued to manufacturer specifications - generic torque values are NOT acceptable for safety-critical suspension components
2. Suspension bushings must be torqued at ride height (vehicle weight on wheels), never with suspension hanging
3. Upper strut mount orientation must match original installation to maintain proper camber and caster settings
4. Brake lines and ABS sensors must have adequate clearance through full suspension travel and steering range

Verification

• Verify all three upper strut mount nuts are installed and properly torqued on both sides
• Verify lower strut pinch bolts are installed with proper orientation and torqued
• Check that brake lines and ABS wiring have proper clearance and are secured to strut bodies
• Bounce each corner of the vehicle and verify struts dampen movement properly without noise
• Verify no suspension components contact the frame or body through full suspension travel
• Test drive in a safe area at low speed (under 25 mph) to check for abnormal noises, vibration, or handling issues
• MANDATORY: Have vehicle professionally aligned before normal operation. Check and record alignment within 50 miles of repair
• After first 50-100 miles, re-check all suspension fastener torque values

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