This procedure covers the removal and replacement of the radius arm bushings on the front suspension of a 2024 Rivian EDV 500 Dual Motor AWD electric delivery van.

Warnings

Tools required

Parts

• Radius arm bushing (front) × 1 — Use OEM specification
• Radius arm bushing (rear) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery negative terminal
4. If equipped with air suspension, set to service mode or exhaust air from system per manufacturer procedure
5. Raise vehicle on lift or use floor jack with jack stands at manufacturer-specified lift points
6. Remove front wheel on side being serviced
7. Spray all suspension fasteners with penetrating oil and allow to soak
8. Mark orientation of radius arm to frame and axle mounting points for reassembly reference

Procedure

1. 1

   Support front suspension
   Position a hydraulic floor jack under the lower control arm or knuckle assembly to support the weight of the suspension. Raise slightly to unload the radius arm but do not lift the vehicle. This prevents sudden collapse when fasteners are removed.
2. 2

   Remove front radius arm mounting bolt
   Locate the front mounting point where the radius arm attaches to the frame rail. Remove the through-bolt and nut securing the radius arm to the frame bracket. Note the orientation of any washers or spacers. The bushing will remain captured in the radius arm eye at this point.
3. 3

   Remove rear radius arm mounting bolt
   Locate the rear mounting point where the radius arm attaches to the axle housing or knuckle assembly. Remove the through-bolt and nut. Support the radius arm as you remove the final fastener to prevent it from dropping.
4. 4

   Remove radius arm from vehicle
   Carefully lower and remove the radius arm from the vehicle. Inspect the mounting brackets on both frame and axle for damage, cracks, or excessive wear. Clean mounting surfaces with wire brush if corroded.
5. 5

   Remove old bushings from radius arm
   Using a hydraulic press or bushing press tool, press out the old bushings from both ends of the radius arm. Note the orientation and depth of the original bushings before removal. The bushings may be bonded or press-fit. Apply steady pressure and ensure the arm is properly supported to prevent distortion.
6. 6

   Clean radius arm bushing bores
   Thoroughly clean the bushing bores in both ends of the radius arm using a wire brush and solvent. Remove all rubber residue, corrosion, and debris. Inspect the bores for cracks, elongation, or damage. Replace the radius arm if the bores are damaged.
7. 7

   Install new bushings
   Apply a light coating of soapy water or bushing installation lubricant to the outer sleeve of the new bushings. Using the hydraulic press or bushing press tool, carefully press the new bushings into the radius arm bores. Ensure bushings are oriented correctly per manufacturer specifications and pressed to the correct depth (typically flush or to a specified measurement). Do not use petroleum-based lubricants as they can degrade rubber bushings.
8. 8

   Install radius arm to rear mounting point
   Position the radius arm to the rear mounting bracket on the axle housing or knuckle assembly. Align the holes and insert the through-bolt. Install the nut but do not fully tighten at this time. Leave fasteners finger-tight to allow for alignment.
9. 9

   Install radius arm to front mounting point
   Align the front eye of the radius arm with the frame bracket mounting point. You may need to use a pry bar or jack to align holes. Insert the through-bolt with any washers or spacers in their original orientation. Install the nut finger-tight.
10. 10

    Load suspension to ride height
    Using the floor jack under the lower control arm or knuckle, raise the suspension to normal ride height. This ensures the bushings are torqued at their operational position, preventing premature wear. Match the suspension position to vehicle weight distribution if possible.
11. 11

    Torque all radius arm fasteners
    With suspension at ride height, torque the front and rear radius arm mounting bolts and nuts to manufacturer specification. Since torque specifications are not available in the database, consult the Rivian service manual for exact values. Torque in the sequence specified by the manufacturer. Do not torque fasteners with suspension hanging or extended.
12. 12

    Remove support jack and reinstall wheel
    Carefully lower and remove the floor jack from under the suspension. Reinstall the front wheel and torque lug nuts to specification in a star pattern. Lower vehicle to the ground.

Reassembly

1. Ensure all fasteners are torqued to specification with suspension at ride height
2. Verify no tools or parts have been left in the suspension area
3. Reconnect 12V auxiliary battery negative terminal
4. If air suspension was placed in service mode, return to normal operation and verify function
5. Test drive vehicle at low speed in a safe area to verify no abnormal noises or handling issues

Verification

• Visually inspect all radius arm mounting points to confirm fasteners are properly installed and torqued
• Check for proper suspension articulation with no binding or interference
• Perform a test drive and verify no clunking, knocking, or vibration from the front suspension
• Schedule a four-wheel alignment as soon as possible after this repair, as suspension geometry has been affected
• Re-torque all fasteners after 50-100 miles of driving as bushings settle

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