This procedure covers the removal and replacement of the front sway bar bushings on a 2024 Rivian EDV 500 electric delivery van, restoring proper suspension function and eliminating clunking noises.

Warnings

Tools required

Parts

• Front sway bar bushing set (left and right) × 1 — Use OEM specification
• Sway bar bushing bracket bolts (if corroded) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Allow suspension to settle at normal ride height before beginning work
4. Verify you have obtained proper torque specifications from Rivian service documentation
5. Spray sway bar bushing bracket bolts with penetrating lubricant and allow to soak for 15-20 minutes

Procedure

1. 1

   Raise and support vehicle
   Using a floor jack, raise the front of the vehicle and support it securely on jack stands positioned at the manufacturer-designated front lift points. Ensure the vehicle is stable before proceeding. The front suspension should be at full droop (extended) to relieve tension on the sway bar.
2. 2

   Remove front wheels
   Remove both front wheels using a 19mm socket to access the sway bar and bushing brackets. Set wheels aside in a safe location.
3. 3

   Locate sway bar bushing brackets
   From underneath the vehicle, locate the front sway bar running laterally across the front subframe. Identify the two bushing brackets that secure the sway bar to the subframe or crossmember, typically positioned near the center of the vehicle on either side of the sway bar.
4. 4

   Support sway bar
   If the sway bar will drop significantly when brackets are removed, support it with a bungee cord or strap to prevent it from hanging on the end links. This prevents stress on the end link connections during bushing replacement.
5. 5

   Remove first bushing bracket
   Starting with the driver side, remove the bolts securing the sway bar bushing bracket to the subframe. There are typically two bolts per bracket. Use a socket and ratchet, working carefully as bolts may be tight. Remove the bracket and old bushing from the sway bar.
   ⚠Do not allow the sway bar to drop suddenly - it may damage brake lines or ABS sensor wiring
6. 6

   Inspect sway bar mounting surface
   Examine the area of the sway bar where the bushing was mounted. Look for corrosion, wear marks, or damage. Use a wire brush to clean the mounting surface area, removing any rust, old rubber residue, or debris. The surface should be clean and smooth for proper bushing contact.
7. 7

   Install new bushing on driver side
   Apply a light coat of silicone spray lubricant to the inside of the new bushing and the cleaned sway bar surface. Position the new bushing around the sway bar in the correct orientation - most bushings have a split that should face forward or as indicated by the replacement part instructions. Ensure the bushing is centered on the bar where the bracket will clamp it.
8. 8

   Install driver side bracket
   Position the bushing bracket over the new bushing and align the bracket bolt holes with the mounting points on the subframe. Start both bracket bolts by hand to ensure proper thread engagement. Once both bolts are started, tighten them evenly in a cross-pattern to the manufacturer-specified torque value.
9. 9

   Remove passenger side bushing bracket
   Repeat the removal process for the passenger side bushing bracket. Remove both bolts securing the bracket to the subframe, then remove the bracket and old bushing from the sway bar.
10. 10

    Clean and prepare passenger side
    Clean the passenger side sway bar mounting surface with a wire brush, removing all corrosion, old rubber material, and debris. Ensure the surface is clean and dry before installing the new bushing.
11. 11

    Install new passenger side bushing
    Apply silicone spray lubricant to the inside of the new bushing and the sway bar surface. Install the bushing around the sway bar in the proper orientation, ensuring it is centered in the mounting location and the split faces the correct direction matching the driver side installation.
12. 12

    Install passenger side bracket
    Position the bracket over the new bushing, align the mounting holes, and start both bolts by hand. Tighten both bolts evenly in a cross-pattern to the manufacturer-specified torque value, ensuring the bushing is properly compressed and seated.
13. 13

    Reinstall wheels
    Reinstall both front wheels, threading the lug nuts by hand first to prevent cross-threading. Tighten the lug nuts in a star pattern to seat the wheel properly, but do not torque fully while vehicle is on jack stands.
14. 14

    Lower vehicle and final torque
    Carefully remove jack stands and lower the vehicle to the ground. Once the vehicle weight is fully on the wheels, perform final torque on all wheel lug nuts to manufacturer specification (typically 130-140 ft-lbs for Rivian vehicles) using a star pattern.

Reassembly

1. All hardware should be torqued to Rivian specifications - verify torque values before operation
2. Ensure both bushings are properly seated and brackets are secure with no gaps
3. Verify sway bar moves freely without binding and is not contacting any brake lines or cables
4. Do not use petroleum-based lubricants on bushings as they will degrade the rubber

Verification

• Start the vehicle and verify no warning lights are illuminated on the dash
• Perform a slow test drive and listen for clunking or rattling noises from the front suspension - bushings should eliminate previous noise
• Drive over speed bumps or rough pavement at low speed to verify sway bar is functioning properly and bushings are seated correctly
• Perform a visual inspection under the vehicle after test drive to ensure all brackets remain tight and properly positioned
• Check that steering response feels normal and vehicle does not exhibit excessive body roll in turns

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