This procedure covers the removal and installation of the front or rear subframe assembly on the 2024 Rivian EDV 500, including disconnection of suspension, steering, and drivetrain components.

Warnings

Tools required

Parts

• Subframe mounting bolts × 1 — Use OEM specification
• Control arm hardware (if damaged) × 1 — Use OEM specification
• Steering rack bolts (if damaged) × 1 — Use OEM specification
• Stabilizer bar link hardware × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Connect scan tool and access service mode. Disable high-voltage system following Rivian safety procedures and verify zero voltage.
3. Depressurize air suspension system through scan tool and set to 'Jack Mode' if available.
4. Disconnect 12V auxiliary battery negative terminal.
5. Raise vehicle on lift to working height ensuring proper lift point contact per Rivian specifications.
6. Remove all four wheels and set aside.
7. Support vehicle with jack stands at designated frame support points as backup safety measure.
8. Document and photograph suspension geometry, alignment shims, and connector locations for reference during reassembly.
9. Spray all subframe mounting bolts and suspension hardware with penetrating oil and allow to soak.

Procedure

1. 1

   Disconnect air suspension lines and electrical connections
   Locate air suspension lines at each corner connected to the subframe being serviced. Press release collar and disconnect air lines from suspension struts. Disconnect ride height sensors and any ABS wheel speed sensor connectors attached to suspension components. Label all connectors with tape and marker for proper reconnection.
2. 2

   Remove stabilizer bar end links
   Support stabilizer bar with jack or wire. Remove stabilizer bar end link nuts from both sides of the subframe using appropriate socket while holding stud with wrench to prevent spinning. Disconnect stabilizer bar from control arms or struts. If servicing front subframe, note any steering rack heat shields or covers that must be removed.
3. 3

   Disconnect lower control arms from knuckles
   Remove lower ball joint pinch bolts or castle nuts (depending on design) connecting control arms to steering knuckles. Use ball joint separator tool to break taper fit between ball joint stud and knuckle. Do not damage ball joint boots. Allow knuckle assembly to pivot upward and secure with wire or bungee cord to prevent strain on CV axle or brake lines.
4. 4

   Disconnect steering rack from subframe (front subframe only)
   Locate steering rack mounting bolts securing rack to front subframe. Support steering rack with separate jack or transmission jack. Remove steering rack mounting bolts but do not disconnect steering shaft or hydraulic/electrical connections. Lower steering rack slightly and secure out of the way with wire or stands. Ensure no tension is placed on steering shaft universal joint.
5. 5

   Disconnect drivetrain components from subframe
   For front subframe: disconnect front motor mounting bolts if motor mounts to subframe. For rear subframe: support rear drive unit with transmission jack and disconnect motor/drive unit mounting bolts from subframe. Leave electrical connectors and coolant lines attached to motor but ensure adequate slack to lower subframe. If differential is subframe-mounted, support separately.
6. 6

   Disconnect brake lines and ABS components
   Locate any brake lines, ABS lines, or brake hose brackets mounted to subframe. Remove bracket mounting bolts to free lines from subframe but do NOT disconnect brake lines unless absolutely necessary. If brake lines must be disconnected, prepare to bleed brake system during reassembly. Secure all lines with wire away from subframe drop zone.
7. 7

   Position subframe support fixture
   Position transmission jack or dedicated subframe support fixture under the center of the subframe. The fixture should have multiple contact points to prevent subframe from shifting. Raise jack until it just contacts subframe and takes slight load. Subframe should still be supported by mounting bolts at this point. Use adjustable arms or wood blocks to ensure even support across entire subframe width.
8. 8

   Remove subframe mounting bolts
   Locate all subframe-to-chassis mounting bolts (typically 4-6 bolts depending on front or rear). Using breaker bar, loosen but do not remove subframe mounting bolts while subframe is still supported by jack. Note position of any alignment shims, spacers, or dowel pins at mounting points. Remove bolts completely and store in organized manner noting their original positions.
9. 9

   Lower subframe assembly
   Carefully lower transmission jack while monitoring all attached components, wiring harnesses, and lines. Have assistant verify nothing is snagging or binding as subframe lowers. Lower subframe approximately 6 inches at a time, stopping to verify clearance. Continue lowering until subframe is completely free of vehicle and can be rolled away. Inspect all mounting points on chassis for damage or corrosion.
10. 10

    Inspect and prepare subframe and mounting points
    Inspect removed subframe for cracks, damage, or corrosion. Check all mounting bushings and brackets for wear or deterioration. Clean subframe mounting surfaces on chassis using wire brush. Inspect chassis mounting points for thread damage and run tap through if necessary. If installing new subframe, transfer any reusable components (bushings, brackets, heat shields) from old unit. Clean and inspect all fasteners; replace any damaged or heavily corroded hardware.

Reassembly

1. Clean all mounting bolt threads and apply anti-seize compound to threads (not on friction surfaces).
2. Raise subframe back into position using transmission jack, carefully aligning with chassis mounting points and any dowel pins.
3. Install subframe mounting bolts hand-tight first, then torque in cross-pattern sequence per Rivian specifications (consult service manual for exact values).
4. Reconnect drive unit/motor mounting bolts and torque to specification. Reconnect steering rack to front subframe if applicable.
5. Reconnect lower control arm ball joints to steering knuckles and install new castle nuts or pinch bolts. Torque to specification.
6. Reattach stabilizer bar end links and torque fasteners to specification.
7. Reconnect all brake line brackets, ABS sensor connectors, and ride height sensor connectors.
8. Reconnect air suspension lines ensuring they click securely into place. Verify no damage to O-rings.
9. Reinstall wheels and torque lug nuts in star pattern to specification.
10. Remove jack stands and lower vehicle to ground.

Verification

• Reconnect 12V battery and enable high-voltage system through scan tool following proper procedure.
• Use scan tool to repressurize air suspension system and verify all corners respond properly.
• Check for any fault codes related to suspension, steering, or drivetrain systems and clear if installation-related.
• Perform visual inspection underneath vehicle verifying all connections are secure and no components are binding.
• Start vehicle and verify no unusual noises from suspension or drivetrain areas.
• Perform a slow test drive in safe area checking for proper steering response, suspension operation, and drivetrain engagement.
• Schedule four-wheel alignment immediately as subframe removal will affect suspension geometry.
• Recheck all subframe mounting bolt torque after 50-100 miles of driving.

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