This procedure covers the removal and replacement of the leaf spring shackle on a 2024 Rivian EDV 500 commercial delivery van, including suspension disassembly and proper alignment.

Warnings

Tools required

Parts

• Leaf spring shackle kit × 1 — Use OEM Rivian specification
• Shackle bushings × 2 — Use OEM Rivian specification
• Shackle bolts × 2 — Use OEM Rivian specification
• Lock nuts × 2 — Use OEM Rivian specification
• Anti-seize compound × 1 — Copper-based

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks in front of front wheels
3. Open rear cargo doors to access 12V battery disconnect switch in rear electrical compartment
4. Disconnect 12V battery using disconnect switch and wait 2 minutes for systems to power down
5. Loosen rear wheel lug nuts while vehicle is on ground
6. Apply penetrating lubricant to all shackle bolt threads and allow to soak for 15-30 minutes

Procedure

1. 1

   Raise and support vehicle
   Using a floor jack at the rear frame rail jacking point, raise the rear of the vehicle. Position heavy-duty jack stands under the frame rails ahead of the rear axle. Lower vehicle onto jack stands. Ensure stands are secure and vehicle is stable before proceeding.
2. 2

   Remove rear wheel
   Remove the lug nuts completely and remove the rear wheel on the side where shackle replacement is needed. Store wheel away from work area.
3. 3

   Support leaf spring assembly
   Position a floor jack with a wood block under the rear axle near the leaf spring to support the weight of the axle and spring assembly. Raise jack slightly to take load off the shackle but do not lift axle. The spring should be in a neutral, unloaded position.
4. 4

   Remove lower shackle bolt
   Locate the lower shackle bolt connecting the shackle to the rear spring eye. Using appropriate socket, remove the nut from the bolt. If bolt is seized, apply additional penetrating lubricant and use a breaker bar. Drive the bolt out using a drift punch and hammer if necessary. Support the shackle as the bolt is removed.
5. 5

   Remove upper shackle bolt
   Locate the upper shackle bolt connecting the shackle to the frame bracket. Remove the nut from the bolt. Drive or tap the bolt out of the frame bracket and shackle. The shackle assembly should now be free to remove.
6. 6

   Remove shackle assembly
   Remove the complete shackle assembly from the vehicle. Inspect the spring eye and frame bracket for damage, cracks, or excessive wear. Wire brush all mounting surfaces to remove rust and debris.
7. 7

   Inspect and clean mounting points
   Thoroughly inspect the rear spring eye and frame shackle bracket for cracks, elongated holes, or damage. Clean all bolt holes with a wire brush. Check that bolts pass freely through frame and spring eye holes. If holes are worn or elongated, additional frame or spring repairs may be required.
8. 8

   Prepare new shackle assembly
   Inspect new shackle for correct part number and verify bushings are properly installed. Apply a thin coat of anti-seize compound to bolt threads and contact surfaces. Do not apply lubricant to bushing surfaces that contact bolts.
9. 9

   Install upper shackle bolt
   Position the new shackle to the frame bracket. Insert the upper shackle bolt through the frame bracket and shackle. Start the lock nut on the bolt threads but do not tighten at this time. Ensure bolt is fully seated through both frame bracket sides.
10. 10

    Install lower shackle bolt
    Align the lower portion of the shackle with the rear spring eye. You may need to use the floor jack to adjust axle height slightly to align holes. Insert the lower shackle bolt through the spring eye and shackle. Start the lock nut on the bolt threads but do not tighten.
11. 11

    Position suspension at ride height
    Using the floor jack under the axle, carefully raise or lower the axle until the suspension is at approximately normal ride height position. This ensures bushings are torqued in their neutral operating position, preventing premature bushing failure.
12. 12

    Torque shackle fasteners
    With suspension at ride height, torque both upper and lower shackle bolt nuts to manufacturer specification. Since torque specifications are not available in the database, follow the torque values marked on the new hardware packaging or Rivian service documentation. Typical specifications for commercial vehicle leaf spring shackles range from 100-150 ft-lbs. Hold bolt head with wrench while torquing nut.
13. 13

    Remove support jack and reinstall wheel
    Lower and remove the floor jack from under the axle. Reinstall the rear wheel and hand-tighten lug nuts in a star pattern. Do not fully torque lug nuts until vehicle is on the ground.
14. 14

    Lower vehicle
    Carefully raise vehicle slightly with floor jack to remove jack stands. Lower vehicle completely to the ground. Remove wheel chocks.
15. 15

    Final torque and system check
    Torque wheel lug nuts to specification in a star pattern. Reconnect 12V battery using disconnect switch in rear electrical compartment. Start vehicle and verify no warning lights related to suspension or drivetrain systems are present.

Reassembly

1. Ensure both shackle bolts are torqued with suspension at ride height to prevent bushing bind
2. Verify all fasteners are fully tightened and lock nuts are properly seated
3. Check that leaf spring moves freely through its range of motion without binding at shackle

Verification

• Visually inspect shackle installation to ensure proper alignment and clearance
• Bounce rear of vehicle and listen for any squeaks, rattles, or unusual noises from shackle area
• Test drive vehicle at low speed and verify normal suspension operation and handling
• Re-inspect all fasteners after 50-100 miles of driving to ensure proper torque retention
• Schedule alignment check if vehicle pulls to one side or if both shackles were replaced

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