This procedure covers the removal and replacement of leaf spring bushings on the 2024 Rivian EDV 500 commercial delivery van, addressing wear or damage to the rear suspension mounting points.

Warnings

Tools required

Parts

• Leaf spring bushing (front or rear position) × 2 — Use OEM specification
• Leaf spring shackle bushing (if applicable) × 2 — Use OEM specification
• U-bolt hardware kit (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks on front wheels
3. Access the high voltage disconnect using Rivian service mode through the center screen: Service Menu > HV Disconnect > Confirm
4. Wait 5 minutes after HV disconnect for capacitor discharge
5. Use multimeter to verify zero voltage at HV junction box under vehicle
6. Apply lockout/tagout tag to HV disconnect location
7. Raise vehicle on lift to working height with rear axle accessible
8. Remove rear wheels on the side being serviced
9. Spray all leaf spring mounting hardware with penetrating oil and allow 15 minutes to soak
10. Support rear axle with hydraulic floor jack positioned at differential housing center

Procedure

1. 1

   Remove wheel speed sensor and brake line brackets
   Disconnect the rear wheel speed sensor connector and unbolt sensor from axle housing. Remove any brake line mounting brackets attached to the axle or leaf spring assembly that will interfere with bushing access. Secure brake lines away from work area with mechanics wire to prevent damage.
2. 2

   Mark and document spring orientation
   Using paint marker or scribe, mark the relationship between leaf spring center bolt, spring eye orientation, and frame mounting bracket. Take detailed photos of spring positioning, shackle angle, and any alignment shims. This documentation is critical for maintaining correct axle alignment during reassembly.
3. 3

   Remove U-bolt nuts and plates
   Remove the four U-bolt nuts securing the leaf spring pack to the axle housing. Note the torque specification is not available in the database, but hardware should be replaced if threads are damaged. Remove the U-bolt top plate and carefully extract U-bolts from spring pack. Keep axle supported with floor jack.
4. 4

   Detach rear spring shackle
   Support the rear of the leaf spring with a second jack or support stand. Remove the lower shackle bolt nut and washer. Drive out the shackle bolt using a brass drift and hammer, working from the nut side. The spring should now pivot on the front mounting only.
5. 5

   Remove front spring mounting bolt
   While supporting the leaf spring assembly, remove the front spring eye mounting bolt nut. Drive out the front pivot bolt using appropriate drift tool. The leaf spring assembly can now be lowered away from the vehicle. Handle carefully as spring pack is heavy (approximately 40-50 lbs for EDV configuration).
6. 6

   Remove leaf spring from vehicle
   Carefully lower and remove the entire leaf spring assembly from the vehicle. Place on clean work surface for bushing service. Inspect spring leaves for cracks, delamination, or damage while removed. If spring pack shows damage, replacement is recommended rather than bushing service alone.
7. 7

   Press out worn bushings
   Secure the spring eye in appropriate fixture on bushing press. Select correct size receiver cup for EDV bushing (typically 2.5 inch OD). Position press adapter against inner bushing sleeve and apply steady pressure to press bushing out of spring eye. Repeat for second bushing location (rear eye or shackle mount). Clean bushing bore thoroughly with wire brush and inspect for cracks or elongation.
8. 8

   Prepare and install new bushings
   Verify new bushings match OEM specification for EDV application (commercial duty rated). Apply thin coat of supplied bushing lubricant to outer diameter of bushing and inner bore of spring eye. Do not use petroleum-based lubricants as they degrade polyurethane bushings. Position bushing squarely in spring eye bore using alignment tool.
9. 9

   Press in new bushings
   Using bushing press with correctly sized driver adapter, press new bushing into spring eye until fully seated and flush with both sides of eye. Bushing should be centered with equal protrusion on both sides. Apply steady, even pressure - do not impact or hammer. Verify bushing orientation if directional (some designs have offset inner sleeves). Repeat for second bushing location.
10. 10

    Reinstall leaf spring assembly
    Position leaf spring assembly back into vehicle mounting location, aligning with marks made during disassembly. Support spring with jack at center point. Install front spring eye bolt through frame bracket and new bushing, ensuring bolt enters squarely. Install washer and nut finger tight - do not torque until vehicle is at ride height.
11. 11

    Attach rear shackle
    Align rear spring eye with shackle bracket. Install shackle bolt through frame bracket, bushing, and shackle link. Install washer and nut finger tight. Verify shackle moves freely and is not binding. Do not torque fasteners at this stage.
12. 12

    Reposition axle and install U-bolts
    Using floor jack, carefully raise axle housing to contact leaf spring pack at original position. Verify spring center bolt locates properly in axle spring pad. Install U-bolts over axle housing and through spring pack. Position top plate and install nuts in cross pattern. Tighten gradually in multiple passes to prevent spring pack distortion. Final torque values not available in database - follow Rivian service information.
13. 13

    Reconnect brake and sensor components
    Reinstall brake line mounting brackets to axle or spring assembly. Reconnect wheel speed sensor and secure wiring with original clips. Ensure no wiring is pinched or under tension that could cause failure during suspension movement.
14. 14

    Lower vehicle and torque fasteners at ride height
    Install rear wheel and lower vehicle until suspension is at normal ride height with full weight on wheels. This is critical - leaf spring bushing fasteners must be torqued at ride height to prevent bushing bind and premature failure. Torque front spring eye bolt, shackle bolts, and U-bolt nuts per Rivian service specifications. Re-verify all torque values after 50 miles of operation.
15. 15

    Restore high voltage system and verify operation
    Remove lockout/tagout tag. Restore high voltage system through service mode menu. Verify all electrical systems return to normal operation. Clear any suspension or stability control system faults using Rivian diagnostic system. Test drive vehicle to verify proper suspension operation and absence of clunks or binding.

Reassembly

1. All leaf spring pivot fasteners must be torqued at normal ride height, not with suspension hanging
2. Verify U-bolts are tightened evenly in cross pattern to prevent spring pack distortion
3. Apply anti-seize compound to shackle and pivot bolt threads during reassembly
4. Replace any hardware showing thread damage or corrosion
5. Perform alignment check after completing bushing replacement on both sides

Verification

• Test drive vehicle at low speed and verify no clunking, binding, or unusual noises from rear suspension
• Verify rear axle tracking is straight with no dog-tracking condition
• Check that vehicle sits level side-to-side at normal ride height
• Confirm all wheel speed sensors are functioning properly with no ABS warning lights
• Schedule four-wheel alignment within 50 miles of completion to verify axle position
• Re-torque all spring mounting fasteners after 50 miles and 500 miles of operation
• Monitor for any high voltage system warnings after restoration - none should be present

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