This procedure covers the removal and replacement of the leaf spring on a 2024 Rivian EDV 500 commercial electric van with dual motor AWD configuration.

Warnings

Tools required

Parts

• Leaf spring assembly × 1 — Use OEM Rivian specification
• Leaf spring U-bolts × 1 — Use OEM specification
• Shackle bushings × 2 — Use OEM specification
• Front eye bushing × 1 — Use OEM specification
• Shackle pins or bolts × 2 — Use OEM specification
• U-bolt nuts and washers × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Place wheel chocks in front of wheels that will remain on ground
3. If required by service position, disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
4. Loosen lug nuts on the wheel(s) corresponding to the leaf spring being replaced while vehicle is still on ground
5. Raise vehicle using approved lifting points specified in Rivian EDV 500 service manual
6. Support vehicle on heavy-duty jack stands at frame rails - never rely solely on floor jack
7. Remove wheel and tire assembly
8. Spray all leaf spring mounting hardware with penetrating oil and allow to soak for 15-20 minutes
9. Visually inspect surrounding high-voltage components and ensure no damage to protective covers

Procedure

1. 1

   Support the rear axle
   Position a floor jack under the rear axle housing near the leaf spring mounting location. Raise jack just enough to make light contact and support the axle weight. This prevents the axle from dropping when the spring is removed and maintains proper alignment of components.
2. 2

   Disconnect shock absorber lower mount
   Locate the shock absorber lower mounting bolt at the axle. Remove the lower shock mounting bolt and carefully move the shock absorber out of the way. Secure it with a zip tie or bungee cord to prevent damage to the shock or surrounding components.
3. 3

   Remove U-bolt nuts
   Remove the four nuts securing the U-bolts that clamp the leaf spring to the axle housing. Keep the U-bolt plate and hardware together for reference during reassembly. Note the orientation of any locating tabs or alignment features on the U-bolt plate.
4. 4

   Remove U-bolts
   Carefully remove the U-bolts from the axle and spring assembly. If U-bolts are corroded or difficult to remove, tap them upward with a hammer. Inspect U-bolts for damage, corrosion, or deformation - replacement is recommended even if they appear serviceable.
5. 5

   Remove rear shackle
   Remove the bolt(s) securing the rear shackle to the frame bracket. Then remove the bolt securing the shackle to the rear eye of the leaf spring. Support the spring as you remove the final fastener. Note the orientation of bushings and any shims or spacers present.
6. 6

   Remove front spring mount
   Remove the bolt or pin securing the front eye of the leaf spring to the front hanger bracket on the frame. The spring should now be free from the vehicle. Carefully lower and remove the leaf spring assembly, watching for any wiring harnesses or brake lines that may be routed nearby.
7. 7

   Inspect mounting points
   With the spring removed, thoroughly inspect all mounting brackets, hangers, and frame attachment points for cracks, deformation, or excessive corrosion. Check the axle spring pad for damage. Use a wire brush to clean all mounting surfaces on the frame and axle.
8. 8

   Prepare new leaf spring
   Unpack the new leaf spring assembly and verify it matches the original configuration. Install new bushings in the spring eyes if not pre-installed. Apply a light coating of appropriate lubricant to bushings per manufacturer specification. Check that all spring leaves are properly aligned and center bolt is tight.
9. 9

   Install front spring mount
   Position the new leaf spring with the front eye aligned to the front hanger bracket. Install the front mounting bolt or pin through the spring eye and bracket. Thread the fastener but do not fully torque at this time - leave it loose enough to allow spring movement for rear shackle installation.
10. 10

    Install rear shackle
    Position the rear shackle between the rear spring eye and frame bracket. Install the bolt through the spring eye and shackle, then install the bolt through the shackle and frame bracket. Thread fasteners but do not torque yet. Ensure proper alignment and that no binding occurs.
11. 11

    Position spring on axle
    Use the floor jack to carefully raise the axle until the spring seats properly on the axle spring pad. Verify the spring center bolt locates in the hole in the axle pad. Ensure any alignment features are properly engaged and the spring is centered on the axle.
12. 12

    Install U-bolts
    Position the new U-bolts over the axle and through the spring. Install the U-bolt plate and thread all four nuts onto the U-bolts. Start all nuts before tightening any. Tighten nuts in a cross pattern gradually to ensure even clamping force. Without torque specifications available, tighten to manufacturer specification from service manual or follow OEM guidelines.
13. 13

    Reconnect shock absorber
    Remove any securing ties from the shock absorber. Align the shock with its lower mounting point and install the lower mounting bolt. Tighten to specification per service manual.
14. 14

    Torque all fasteners at ride height
    Lower the vehicle so the suspension is at normal ride height (vehicle weight on suspension but still accessible). Torque the front spring eye bolt, rear shackle bolts, and U-bolt nuts to manufacturer specifications in that order. This ensures proper bushing orientation and prevents premature bushing failure. Verify shock absorber fastener is properly torqued.

Reassembly

1. Install wheel and tire assembly, hand-tightening lug nuts in a star pattern
2. Lower vehicle to ground and remove jack stands
3. Torque lug nuts to Rivian specification in star pattern
4. If 12V battery was disconnected, reconnect negative terminal and verify all systems initialize properly
5. Remove wheel chocks

Verification

• Perform a visual inspection of all fasteners to ensure proper installation and no missing hardware
• Check that shock absorber is properly connected and not binding through suspension travel
• Verify adequate clearance between leaf spring and all surrounding components including brake lines, wiring harnesses, and battery pack components
• Test drive vehicle at low speed in a safe area and listen for any unusual noises from the suspension
• After test drive, re-check all fastener torques as leaf springs may settle slightly
• Check vehicle ride height and compare to opposite side - significant difference may indicate installation issue
• Verify no warning lights or system faults are present on instrument cluster
• Schedule follow-up inspection after 100-200 miles of driving to re-torque U-bolt nuts as springs settle

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