This procedure covers the removal and replacement of the front lower control arm on a 2024 Rivian EDV 500 electric delivery van with dual motor AWD.

Warnings

Tools required

Parts

• Front lower control arm × 1 — Use OEM specification
• Lower ball joint nut × 1 — Replace if damaged
• Control arm mounting bolts/nuts × 2 — Replace per service manual

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes
4. Verify high voltage system is fully powered down (consult service manual for EDV shutdown procedure)
5. Loosen front wheel lug nuts while vehicle is on ground
6. Raise front of vehicle with floor jack at designated lift point
7. Support vehicle securely on jack stands rated for vehicle weight at manufacturer-specified support points
8. Remove front wheel on side requiring control arm replacement
9. Inspect suspension components for additional wear or damage
10. Photograph suspension assembly orientation for reference during reassembly

Procedure

1. 1

   Support lower suspension
   Position a floor jack under the lower control arm near the ball joint to support the suspension load. Raise jack slightly to take up weight but do not lift the vehicle. This prevents the suspension from dropping when components are disconnected.
2. 2

   Disconnect sway bar link
   Locate the front sway bar end link connection to the lower control arm. Use a wrench to hold the link stud while removing the retaining nut with a socket. Disconnect the sway bar link from the control arm and secure it out of the way with wire or zip ties.
3. 3

   Remove ball joint castle nut
   Remove the cotter pin from the lower ball joint castle nut if equipped. Using a socket and breaker bar, loosen and remove the castle nut securing the ball joint to the steering knuckle. Keep the nut for reference if replacement nuts are needed.
4. 4

   Separate ball joint from knuckle
   Using a ball joint separator or pickle fork, carefully separate the lower ball joint taper from the steering knuckle. Work the separator between the knuckle and control arm, striking firmly with a hammer if necessary. Avoid damaging the ball joint boot if reusing components. Once separated, support the knuckle assembly to prevent strain on brake hoses and ABS wiring.
5. 5

   Remove front control arm mounting bolt
   Locate the front mounting bolt securing the control arm to the front subframe. This bolt typically passes through a bushing at the front of the control arm. Use a socket on the bolt head and wrench on the nut (or vice versa) to remove the fastener completely. Note the orientation of any washers or spacers.
6. 6

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt securing the control arm to the subframe or chassis. This may require accessing from behind the control arm. Remove the bolt completely, again noting the position of any washers, spacers, or alignment shims that must be reinstalled in the same position.
7. 7

   Remove lower control arm
   With all fasteners removed, carefully lower the floor jack supporting the control arm. Guide the control arm out of its mounting position, maneuvering around brake lines, ABS sensors, and any other components. Inspect the mounting points on the subframe for damage or excessive corrosion.
8. 8

   Prepare new control arm
   Unpack the new lower control arm and verify it matches the original. Inspect all bushings, ball joint boot, and mounting points. Apply anti-seize compound to bolt threads if not pre-coated. If the control arm uses serviceable bushings, ensure they are properly pressed in and oriented correctly.
9. 9

   Install new control arm
   Position the new control arm into the mounting location, aligning the front and rear bushing holes with the subframe mounting points. Raise the floor jack to support the control arm at approximately the correct ride height angle. This is critical for proper bushing alignment and prevents pre-loading the bushings.
10. 10

    Install mounting bolts
    Insert the front and rear control arm mounting bolts through the bushings and subframe. Install washers and nuts in their original orientation. Thread the fasteners by hand first to ensure proper alignment. Snug the bolts but do not torque to final specification yet - this must be done at curb height with suspension loaded.
11. 11

    Connect ball joint to knuckle
    Raise the floor jack to lift the control arm ball joint into the steering knuckle taper. Ensure the taper seats fully and cleanly into the knuckle bore. Install the new castle nut and tighten firmly. The nut should align with the cotter pin hole - if not, tighten further to the next alignment point, never loosen to align.
12. 12

    Reconnect sway bar link
    Position the sway bar end link onto the control arm mounting stud. Install the retaining nut and tighten while holding the link stud from rotating. Ensure the link moves freely without binding.
13. 13

    Lower vehicle to load suspension
    Remove the jack stands and carefully lower the vehicle until the suspension is at normal ride height but the wheel is not yet installed. This loads the suspension components to the correct operating angle for final torquing of the control arm bolts.
14. 14

    Torque all fasteners to specification
    With the vehicle at ride height, torque the front and rear control arm mounting bolts to manufacturer specification using a calibrated torque wrench. Torque the ball joint castle nut to specification and install a new cotter pin. Torque the sway bar link nut to specification. All torque values must be obtained from official Rivian service documentation.
15. 15

    Reinstall wheel and final checks
    Raise the vehicle slightly and reinstall the wheel. Torque lug nuts in a star pattern to manufacturer specification. Lower the vehicle completely. Reconnect the 12V battery. Bounce the suspension several times to settle components. Verify all fasteners are properly secured and no tools or parts have been left in the wheel well.

Reassembly

1. All fasteners must be torqued to Rivian OEM specifications - consult official service documentation
2. Control arm bushing bolts must be torqued at curb ride height to prevent bushing damage
3. Always install a new cotter pin in the ball joint castle nut
4. Verify sway bar link moves freely without binding after installation

Verification

• Test drive the vehicle at low speed in a safe area and verify no unusual noises from the suspension
• Perform steering lock-to-lock check to ensure full range of motion without interference
• Verify no rubbing or contact between suspension components and wheels during full articulation
• Schedule a professional wheel alignment immediately after control arm replacement to restore proper suspension geometry
• Re-check all fastener torque after 50-100 miles of driving
• Inspect for any fluid leaks or disturbance of brake lines or ABS wiring

More procedures for this vehicle