This procedure covers the removal and replacement of the leaf spring U-bolt kit on the rear suspension of a 2024 Rivian EDV 500 commercial delivery van.

Warnings

Tools required

Parts

• Leaf spring U-bolt kit (includes U-bolts, nuts, and bottom plate) × 1 — Use OEM specification
• Anti-seize compound × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks in front of both front wheels
3. Disconnect 12V battery negative terminal and wait 2 minutes for systems to power down
4. Loosen rear wheel lug nuts while vehicle is on ground
5. Raise rear of vehicle with floor jack at manufacturer-specified jacking points
6. Support vehicle securely with jack stands rated for weight, positioned under frame rails
7. Remove rear wheel on side being serviced
8. Spray all U-bolt nuts and threads with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Support the rear axle
   Position a hydraulic jack under the rear axle housing near the side being serviced. Raise the jack until it just contacts the axle and takes a small amount of weight, but does not lift the vehicle. This prevents the axle from dropping when U-bolts are removed.
2. 2

   Remove U-bolt nuts
   Using a 19mm or 21mm socket (verify size on your specific hardware), remove all four nuts from the U-bolts. Start by loosening each nut 2-3 turns in a crisscross pattern, then remove completely. Keep nuts if reusing, but replacement is recommended with new U-bolt kit.
3. 3

   Remove U-bolts and bottom plate
   Carefully remove both U-bolts by pulling them downward out of the spring perch. Remove the bottom plate (saddle) from between the axle and leaf spring. Inspect the plate for wear, cracks, or deformation.
4. 4

   Inspect mounting surfaces
   With the U-bolts removed, inspect the leaf spring surface where it contacts the axle for damage, corrosion, or wear. Check the axle spring perch for cracks or deformation. Use a wire brush to clean rust and debris from all mating surfaces on the axle and leaf spring.
5. 5

   Check leaf spring condition
   Visually inspect the leaf spring for cracks, especially at the center where it contacts the axle. Check for broken leaves, separation between leaves, or unusual wear patterns. Replace spring assembly if any damage is found.
6. 6

   Position new bottom plate
   Place the new bottom plate (saddle) from the U-bolt kit between the axle housing and the leaf spring. Ensure it is centered and properly oriented with any alignment features or locating tabs engaged.
7. 7

   Install new U-bolts
   Insert the new U-bolts from the top of the spring perch, threading them through the holes and around the axle housing. Guide the U-bolt legs through the holes in the bottom plate. Apply anti-seize compound to threads before installing nuts.
8. 8

   Hand-tighten U-bolt nuts
   Thread all four U-bolt nuts onto the U-bolt legs by hand. Tighten each nut finger-tight, ensuring the bottom plate remains centered and seated properly against the axle and leaf spring.
9. 9

   Torque U-bolt nuts to specification
   Since manufacturer torque specifications are not available in the database, consult the Rivian service manual or contact a Rivian service center for the exact torque value. Typical U-bolt specifications for commercial vehicles range from 90-150 ft-lb. Tighten nuts in a crisscross pattern in three stages: 50% of final torque, 75% of final torque, then final torque. Verify all four nuts reach the same torque value.
10. 10

    Lower and verify axle position
    Slowly lower the hydraulic jack supporting the axle while observing that the leaf spring remains properly seated in the axle perch. The axle should settle naturally onto the leaf spring without binding or misalignment.
11. 11

    Reinstall wheel
    Reinstall the rear wheel, threading lug nuts by hand initially. Snug lug nuts in a star pattern with a wrench. Lower vehicle to ground before final torque.
12. 12

    Lower vehicle and final torque
    Carefully lower the vehicle from jack stands to the ground. Torque wheel lug nuts to manufacturer specification (typically 150-175 ft-lb for Rivian EDV) in a star pattern.

Reassembly

1. Reconnect 12V battery negative terminal
2. If both sides were serviced, verify equal ride height on both sides
3. Test drive vehicle at low speed and verify no unusual noises or handling issues
4. Re-torque U-bolt nuts after 50-100 miles of driving to account for spring settling

Verification

• Verify all U-bolt nuts are torqued to specification with no gaps between bottom plate and axle
• Confirm leaf spring is properly centered in axle perch with no lateral shift
• Check that vehicle sits level with no sagging on the serviced side
• Test drive vehicle and verify no clunking, squeaking, or handling abnormalities from rear suspension
• Visually inspect U-bolt installation after test drive to ensure nothing has loosened

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