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

Warnings

Tools required

Parts

• Lower control arm assembly × 1 — Use OEM specification for EDV 500
• Lower control arm to frame mounting bolts/nuts × 1 — Use OEM specification
• Ball joint castle nut (if not reusable) × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Verify vehicle is powered off completely
3. Disconnect 12V negative battery terminal and wait 5 minutes for system discharge
4. Loosen wheel lug nuts while vehicle is on ground (do not remove)
5. Raise vehicle with floor jack at designated lift point
6. Support vehicle with jack stands at manufacturer-specified frame support points
7. Remove wheel and tire assembly completely
8. Spray all suspension fasteners with penetrating oil and allow to soak for 10-15 minutes
9. Inspect work area and identify lower control arm mounting points, ball joint connection, and any brackets or components that may interfere

Procedure

1. 1

   Support the knuckle assembly
   Position a floor jack under the steering knuckle or lower control arm to support the weight of the suspension assembly. Raise jack just enough to take light pressure off the ball joint, but do not lift the vehicle. This prevents the suspension from dropping when the control arm is disconnected.
2. 2

   Remove ball joint cotter pin and castle nut
   Locate the ball joint stud where it connects to the steering knuckle. Remove the cotter pin using pliers and discard. Using an appropriate socket, remove the castle nut from the ball joint stud. Do not reuse the cotter pin.
3. 3

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the ball joint taper from the steering knuckle. Insert the tool between the knuckle and control arm at the ball joint connection. Strike the tool firmly or use a press-type separator until the taper releases. Avoid damaging the ball joint boot if reusing the control arm.
4. 4

   Disconnect sway bar link (if equipped)
   If the sway bar end link connects to the lower control arm, support the link and remove the mounting nut. Use a hex key or second wrench to prevent the stud from spinning if necessary. Allow the link to hang or secure with wire to prevent strain on the sway bar.
5. 5

   Remove rear control arm mounting bolt
   Locate the rear mounting point where the control arm attaches to the frame or subframe. This is typically a single through-bolt with a nut on the opposite side. Using a breaker bar and socket, remove the nut while holding the bolt head. Note the orientation and any alignment shims, washers, or eccentric cams. Remove the bolt completely and set aside with hardware.
6. 6

   Remove front control arm mounting bolt
   Locate the front mounting point where the control arm attaches to the frame or subframe. Remove the nut and bolt in the same manner as the rear mount. This may require supporting the control arm to prevent it from dropping. Note any alignment components or bushing orientation for reassembly.
7. 7

   Remove lower control arm
   With both frame mounting bolts removed and ball joint disconnected, carefully maneuver the lower control arm out of the suspension assembly. It may be necessary to lower the support jack slightly or angle the arm to clear other components. Inspect the mounting bushings and ball joint for wear patterns.
8. 8

   Clean mounting surfaces
   Use a wire brush to clean all mounting surfaces on the frame/subframe where the control arm bushings seat. Remove any rust, debris, or old anti-seize compound. Inspect the mounting holes for elongation or damage. Clean the steering knuckle taper bore where the ball joint seats.
9. 9

   Install new lower control arm
   Position the new lower control arm into place, aligning the mounting bushings with the frame/subframe brackets. Insert the front mounting bolt first, but do not tighten. Install the rear mounting bolt, ensuring any alignment shims or cams are positioned exactly as they were during removal. Thread nuts onto bolts by hand.
10. 10

    Connect ball joint to knuckle
    Raise the support jack under the control arm to align the ball joint stud with the hole in the steering knuckle. The taper should seat firmly into the knuckle bore. Install the castle nut and tighten by hand until snug. Do not fully torque at this time.
11. 11

    Reconnect sway bar link (if equipped)
    If disconnected, reconnect the sway bar end link to the lower control arm. Install the mounting nut and tighten to bring components into proper alignment. Use a hex key or wrench to prevent stud rotation.
12. 12

    Load suspension to ride height
    With all components loosely connected, raise or lower the support jack under the control arm or knuckle until the suspension is at approximate ride height (simulating vehicle weight on wheels). This is critical for proper bushing alignment and longevity. Control arm mounting bolts must be torqued at ride height, not full droop or full compression.
13. 13

    Torque all fasteners
    With suspension at ride height, torque the front and rear control arm mounting bolts/nuts to manufacturer specification (consult service manual for exact values, typically 125-175 ft-lbs for EDV applications). Torque the ball joint castle nut to specification (typically 75-100 ft-lbs). Align castle nut slots with cotter pin hole, tightening further if necessary to align (never loosen to align). Install new cotter pin and bend ends. Torque sway bar link nut if equipped.
14. 14

    Remove support jack and reinstall wheel
    Carefully lower and remove the support jack from under the suspension. Reinstall the wheel and tire assembly, threading lug nuts by hand. Lower the vehicle until tire just touches ground, then torque lug nuts to specification in a star pattern (typically 150 ft-lbs for EDV 500, verify in service manual).

Reassembly

1. Lower vehicle completely to ground and remove jack stands
2. Reconnect the 12V negative battery terminal
3. Perform a bounce test on the repaired corner to verify proper installation and no abnormal noises
4. Verify all tools and parts have been removed from work area

Verification

• Start vehicle and verify no warning lights related to suspension or stability control systems
• Test drive vehicle at low speeds in a safe area, checking for unusual noises, vibrations, or pulling
• Schedule immediate four-wheel alignment at a facility equipped to handle commercial electric vehicles
• After alignment, verify steering wheel is centered and vehicle tracks straight
• Re-check all fastener torques after first 50-100 miles of driving

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