Knuckle/Spindle - Rear

This procedure covers the removal and replacement of the rear wheel knuckle/spindle assembly on a 2024 Rivian EDV 500 commercial delivery van with dual motor AWD.

Warnings

Tools required

Parts

• Rear wheel knuckle/spindle assembly × 1 — Use OEM specification
• Wheel hub bearing (if integrated) × 1 — Use OEM specification
• Axle nut × 1 — Single-use fastener
• Ball joint mounting hardware × 1 — Replace if corroded
• Brake caliper mounting bolts × 2 — Replace per service manual
• ABS sensor O-ring × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Place vehicle in service mode and enable transport mode per Rivian service procedures to prevent unexpected motor activation
2. Disconnect the 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
3. Chock the front wheels securely
4. Loosen rear wheel lug nuts while vehicle is on the ground
5. Raise vehicle on lift to working height ensuring proper lift point contact per Rivian specifications
6. Remove rear wheel on affected side
7. Spray all fasteners with penetrating oil and allow to soak for 15 minutes
8. Document or photograph brake caliper bracket orientation and any alignment marks on suspension components

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the two brake caliper mounting bolts and carefully lift the caliper off the rotor. Support the caliper with wire or a bungee cord to prevent strain on the brake hose - do not disconnect the hydraulic line unless the caliper is being replaced. Remove the caliper bracket mounting bolts and remove the bracket. Slide the brake rotor off the hub studs.
2. 2

   Remove wheel speed sensor
   Disconnect the ABS wheel speed sensor electrical connector. Remove the sensor mounting bolt and carefully extract the sensor from the knuckle. Do not pry against the sensor tip as it is fragile. If the sensor is seized, apply penetrating oil and gently work it free using a twisting motion.
3. 3

   Remove axle nut
   Have an assistant apply the parking brake or install a wheel hub holding tool to prevent hub rotation. Use a breaker bar to loosen the rear axle nut (this nut is extremely tight, typically over 200 ft-lb). Remove the axle nut completely and retain any washers. Mark the axle shaft threads with a marker at the point where it exits the hub for reference during reassembly.
4. 4

   Separate tie rod end (if equipped)
   If the EDV 500 rear suspension uses a toe link or tie rod connection to the knuckle, remove the castellated nut and use a ball joint separator tool to disconnect the tie rod end from the knuckle. Do not use excessive force with a pickle fork as this can damage the boot if reusing components.
5. 5

   Disconnect lower control arm
   Support the lower control arm with a jack stand to maintain suspension geometry and prevent sudden dropping. Remove the bolt(s) securing the lower control arm ball joint or bushing to the knuckle. Note any eccentric washers, shims, or alignment adjustment provisions and document their orientation and position for reassembly.
6. 6

   Disconnect upper control arm or strut connection
   Remove the fasteners securing the upper control arm ball joint or strut mounting point to the knuckle. For strut-type suspensions, support the knuckle assembly before removing the final bolts. The knuckle should now be loose but may still be captured on the axle shaft.
7. 7

   Remove knuckle from axle shaft
   Carefully pull the knuckle assembly outward away from the vehicle to separate it from the axle shaft splines. If the hub is stuck on the axle shaft, use a hub puller or slide hammer with appropriate adapters. Do not strike the axle shaft with a hammer as this can damage the motor output bearings. Once separated, guide the knuckle assembly clear of all suspension components and remove it from the vehicle.
8. 8

   Inspect axle shaft and suspension mounting points
   With the knuckle removed, inspect the axle shaft splines for damage, wear, or corrosion. Check the CV joint boot for tears or grease leakage. Examine all suspension mounting points on the control arms and chassis for cracks, elongated holes, or deformation. Clean all mounting surfaces with a wire brush and inspect threaded holes for damage.
9. 9

   Prepare new knuckle assembly
   Unpack the new knuckle assembly and verify it matches the removed part. If the wheel bearing is not pre-installed, press in the new bearing according to Rivian specifications using a hydraulic press and appropriate bearing driver tools. Install a new ABS sensor O-ring on the sensor bore. Apply a thin coat of anti-seize compound to the hub splines where they will contact the axle shaft.
10. 10

    Install knuckle onto axle shaft
    Position the new knuckle assembly and carefully guide it onto the axle shaft splines. Ensure the splines are properly aligned and the knuckle slides on smoothly. If resistance is felt, do not force - remove and check for obstructions or misalignment. Push the knuckle fully onto the axle shaft until it seats against the inner bearing race.
11. 11

    Connect upper and lower control arms
    Raise the knuckle into position and align the upper control arm or strut mounting point. Install mounting bolts finger-tight. Connect the lower control arm to the knuckle, ensuring any alignment shims or eccentric washers are reinstalled in their original positions. Install all fasteners finger-tight but do not torque yet - final torquing must be done at ride height with suspension loaded.
12. 12

    Reconnect tie rod and install axle nut
    If equipped, reconnect the rear tie rod or toe link to the knuckle and install the castle nut. Install a new rear axle nut onto the axle shaft. Using a torque wrench, torque the axle nut to Rivian specifications (consult service manual as torque specs are not provided in this database - typically 180-250 ft-lb for electric vehicle applications). Stake or install the cotter pin as required by design.
13. 13

    Install wheel speed sensor and brake components
    Clean the ABS sensor bore in the knuckle and lubricate the new O-ring with clean brake fluid. Install the wheel speed sensor and torque the mounting bolt per specifications. Reconnect the electrical connector. Install the brake rotor onto the hub. Mount the caliper bracket and torque the mounting bolts. Install the brake caliper and torque the caliper bolts. Pump the brake pedal several times to restore brake pad contact with the rotor.
14. 14

    Lower vehicle and torque suspension fasteners
    Install the wheel and hand-tighten lug nuts. Lower the vehicle until the tires just contact the ground (vehicle at ride height but still supported by lift). With the suspension now loaded, torque all suspension component fasteners to specification in the following order: lower control arm, upper control arm or strut, and tie rod/toe link. This ensures proper bushing preload. Raise vehicle slightly and torque wheel lug nuts in a star pattern.
15. 15

    Bleed brakes and verify installation
    Bleed the rear brake circuit at the affected wheel to remove any air introduced during the procedure. Check brake fluid level and top off with DOT 4 fluid as needed. Reconnect the 12V battery. Exit transport mode and restore normal vehicle operation mode. Test brake pedal feel before moving vehicle.

Reassembly

1. All suspension fasteners must be torqued at ride height with the suspension loaded to ensure proper bushing preload
2. Use new single-use fasteners where specified, including the axle nut
3. Apply medium-strength thread locker to all suspension bolts unless otherwise specified
4. Verify brake caliper slides move freely and brake pads are properly seated before test driving

Verification

• Perform a four-wheel alignment to verify camber, caster, and toe specifications are within Rivian specifications
• Test drive the vehicle at low speed in a safe area and verify no unusual noises, vibrations, or pulling
• Verify ABS system has no fault codes and wheel speed sensor is reading correctly using Rivian diagnostic software
• Recheck all fastener torques after 50-100 miles of driving
• Verify brake pedal feel is firm and brakes operate normally with no pulsation or pulling
• Inspect for any fluid leaks around brake components and differential seals

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