This procedure covers the removal and replacement of the front steering knuckle/spindle assembly on a 2024 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Front steering knuckle assembly × 1 — Use OEM specification
• Axle nut × 1 — Use OEM specification
• Lower ball joint castle nut × 1 — Use OEM specification
• Upper ball joint fasteners × 1 — Use OEM specification
• Tie rod end castle nut × 1 — Use OEM specification
• Brake caliper mounting bolts × 2 — Use OEM specification
• ABS sensor O-ring × 1 — Use OEM specification

Preparation

1. Perform high-voltage system lockout/tagout procedure per Rivian service manual
2. Verify vehicle is on level ground and lift is properly positioned under designated lift points
3. Set parking brake and chock rear wheels
4. Remove front wheel and tire assembly on the side being serviced
5. Support the lower control arm with a jack stand to prevent suspension drop when knuckle is disconnected
6. Place wheel chocks or blocks near work area to prevent tool roll-away

Procedure

1. 1

   Remove brake caliper assembly
   Remove the two brake caliper mounting bolts from the rear of the knuckle. Carefully lift the caliper off the rotor and support it using a caliper hanger or heavy wire attached to the suspension or chassis. Do not allow the caliper to hang by the brake hose.
2. 2

   Remove brake rotor and ABS sensor
   Remove any retaining screws and slide the brake rotor off the hub. Disconnect the ABS wheel speed sensor electrical connector. Remove the sensor mounting bolt and carefully extract the sensor from the knuckle bore. Inspect the sensor O-ring and replace if damaged.
3. 3

   Remove axle nut
   Have an assistant apply the brake pedal or use a pry bar to prevent hub rotation. Using a breaker bar and appropriate socket, remove the front axle nut. This fastener is typically torqued to high specification and may require significant force to loosen. Discard the axle nut as it must be replaced.
4. 4

   Disconnect outer tie rod end
   Remove the cotter pin and castle nut from the outer tie rod end. Use a ball joint separator tool or appropriate pickle fork to separate the tie rod end from the knuckle steering arm. Do not strike the knuckle directly with a hammer as this may cause damage. Mark the tie rod position with paint or a marker for approximate alignment during reassembly.
5. 5

   Disconnect upper ball joint
   Remove the fasteners securing the upper ball joint to the knuckle. On the EDV 500, this typically uses either pinch bolts or through-bolts depending on configuration. Support the knuckle as you remove the final fastener to prevent it from dropping.
6. 6

   Disconnect lower ball joint
   Remove the cotter pin and castle nut from the lower ball joint. Use a ball joint separator tool to separate the ball joint taper from the knuckle. The lower joint may be under significant load even with the control arm supported, so work carefully to avoid sudden release.
7. 7

   Remove CV axle from hub
   Push the CV axle shaft back through the hub bore. If the axle is stuck, use a hub puller or brass drift to carefully tap it free. Support the outer CV joint and axle shaft with wire or a strap to prevent it from hanging and damaging the inner joint or boot.
8. 8

   Remove knuckle assembly
   With all connections separated, carefully maneuver the knuckle assembly away from the vehicle. The knuckle may need to be rotated and angled to clear the CV axle and suspension components. Inspect the mounting surfaces on the control arms and steering linkage for damage or excessive wear.
9. 9

   Inspect and prepare new knuckle
   Compare the new knuckle to the removed unit to verify correct application. Inspect all mounting bores and tapers for damage or debris. Clean the hub bore and bearing mounting surfaces. If the hub bearing is being reused, inspect it for roughness or play. Apply a thin coat of anti-seize to the CV axle splines (avoid getting anti-seize on the hub bearing surface).
10. 10

    Install knuckle to suspension
    Guide the new knuckle into position, threading the CV axle through the hub bore. Align the lower ball joint taper with the knuckle and start the castle nut by hand. Connect the upper ball joint and install fasteners finger-tight. Do not fully tighten any suspension fasteners until the vehicle is at ride height.
11. 11

    Connect tie rod end
    Insert the outer tie rod end into the knuckle steering arm. Install the new castle nut and tighten to specification. Install a new cotter pin, advancing the nut if necessary to align the castle slots with the cotter pin hole. Do not back off the nut to align the cotter pin.
12. 12

    Install axle nut
    Install the new axle nut onto the CV axle shaft and tighten to specification using a torque wrench. Have an assistant apply the brake or use a pry bar to prevent hub rotation during final torque. Stake or lock the nut per manufacturer specification if required.
13. 13

    Install ABS sensor and brake components
    Install a new O-ring on the ABS sensor if applicable. Insert the sensor into the knuckle bore and torque the mounting bolt to specification. Connect the electrical connector. Install the brake rotor and caliper assembly, torquing the caliper mounting bolts to specification.
14. 14

    Final torque all suspension fasteners
    Lower the vehicle until the suspension is at normal ride height (tires just touching the ground with vehicle weight on suspension). Torque all ball joint fasteners and suspension mounting bolts to specification. This step is critical as suspension components must be torqued at ride height to prevent bushing bind and premature wear.
15. 15

    Install wheel and perform systems check
    Install the wheel and tire assembly and torque lug nuts to specification in a star pattern. Remove the high-voltage lockout and restore vehicle to operational status. Clear any diagnostic trouble codes related to ABS sensors or suspension position sensors.

Reassembly

1. All self-locking nuts and castle nuts must be replaced with new parts
2. Suspension fasteners must be torqued at ride height to prevent bushing damage
3. Verify cotter pins are properly installed and bent to prevent loss
4. Check CV boot condition and ensure boot clamps are properly seated after knuckle installation

Verification

• Verify wheel rotates freely without binding or noise from the hub bearing
• Check for proper ABS sensor operation by verifying no ABS warning lights on dash and checking for sensor signal with scan tool
• Perform a steering lock-to-lock check to verify full range of motion without binding
• Test drive vehicle at low speed in a safe area and verify proper steering feel, no pulling, and no unusual noises
• Perform wheel alignment check and adjust as necessary - knuckle replacement will affect alignment angles
• Verify no brake fluid leaks and proper brake pedal feel
• Recheck all fastener torque values after test drive

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