This procedure covers the removal and replacement of the front sway bar (anti-roll bar) on a 2024 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Front sway bar × 1 — Use OEM specification
• Sway bar bushings (pair) × 1 — Use OEM specification
• Sway bar end link bushings/hardware kit × 1 — Use OEM specification or inspect before ordering

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. If equipped, disable adaptive suspension or air suspension per manufacturer guidelines
4. Take reference photos of sway bar installation and routing
5. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
6. Raise front of vehicle and support securely on jack stands at designated lift points
7. Remove both front wheels completely
8. Inspect sway bar, bushings, and end links for wear patterns to identify replacement needs

Procedure

1. 1

   Access sway bar area
   Remove any underbody protective panels or skid plates that obstruct access to the front sway bar. On the EDV 500, this may include forward belly pan sections. Remove fasteners and carefully lower panels, noting their orientation for reinstallation.
2. 2

   Disconnect left sway bar end link
   Locate the left sway bar end link connecting the sway bar to the lower control arm or strut assembly. Using an 18mm wrench on the upper nut and holding the ball stud with a 15mm wrench or hex key, remove the upper mounting nut. If the ball stud spins, use locking pliers or an appropriate tool to hold it. Remove the lower mounting hardware in the same manner to free the end link.
3. 3

   Disconnect right sway bar end link
   Repeat the end link removal process on the right side of the vehicle. Apply penetrating lubricant if fasteners are corroded. Once both end links are disconnected, the sway bar will be free to rotate and move slightly.
4. 4

   Remove sway bar bushing bracket bolts
   Locate the sway bar bushing brackets that secure the bar to the front subframe or chassis rails. Typically there are two brackets, one on each side near the center of the vehicle. Using a 13mm or 15mm socket, remove the bolts securing each bushing bracket to the frame. Support the sway bar with one hand as you remove the final bolts to prevent it from dropping.
5. 5

   Remove sway bar from vehicle
   Carefully maneuver the sway bar out from its mounting position. On the EDV 500, you may need to rotate the bar and work it past steering components, brake lines, or electrical harnesses. Take care not to damage any surrounding components, sensors, or wiring. Remove the bushing brackets and old bushings from the bar.
6. 6

   Clean and inspect mounting points
   Use a wire brush to clean the sway bar mounting surfaces on the subframe or chassis where the bushing brackets attach. Inspect these areas for corrosion, cracks, or damage. Check the frame mounting bolt holes for thread damage or stripped threads. Clean the bushing bracket bolts and inspect threads.
7. 7

   Prepare new sway bar and bushings
   If replacing the sway bar, transfer any necessary components from the old bar to the new one, ensuring proper orientation. Install new sway bar bushings onto the bar in the correct position, noting the split in the bushing should face toward the front or rear as indicated by OEM specifications. Apply a light coating of silicone-based lubricant to the inside of bushings to reduce squeaking (do not use petroleum-based products).
8. 8

   Install sway bar into vehicle
   Carefully maneuver the sway bar back into position, routing it through the same path used during removal. Ensure the bar is oriented correctly with bends and end link mounting points positioned properly. Rotate the bar so the bushing locations align with their mounting positions on the subframe.
9. 9

   Install bushing brackets
   Position the bushing brackets over the bushings and align with the mounting holes on the subframe. Start all mounting bolts by hand to ensure proper thread engagement. Tighten the bushing bracket bolts in a cross pattern to the manufacturer's specified torque (consult Rivian service documentation as no torque spec is currently in database). Do not fully tighten until the vehicle is at ride height with weight on suspension.
10. 10

    Connect sway bar end links
    Position the end links between the sway bar and lower control arm or strut mounting points. Install the mounting hardware at both the upper and lower connections. Hand-tighten all fasteners first, ensuring ball studs are seated properly in their mounting holes. Use a jack under the lower control arm to simulate ride height load if necessary for proper end link alignment.
11. 11

    Torque all fasteners
    With the suspension at or near normal ride height (use jack to load suspension if needed), torque all sway bar bushing bracket bolts and end link fasteners to manufacturer specifications. Consult Rivian service documentation for specific torque values. Typical values range from 35-55 ft-lbs for bushing brackets and 40-65 ft-lbs for end links, but verify for this specific vehicle.
12. 12

    Reinstall underbody panels
    Reinstall all protective panels, skid plates, and belly pans removed during disassembly. Ensure all fasteners are properly secured and panels are correctly aligned.
13. 13

    Reinstall wheels and lower vehicle
    Install both front wheels and hand-tighten lug nuts in a star pattern. Lower the vehicle until wheels just contact the ground but most weight is still on jack stands. Torque wheel lug nuts to specification (typically 130-140 ft-lbs for this vehicle) in a star pattern. Fully lower vehicle and remove jack stands.

Reassembly

1. Ensure all sway bar mounting bolts and end link fasteners are torqued to specification at proper ride height
2. Verify no tools or parts were left in wheel wells or under vehicle
3. Double-check that all underbody panels are securely fastened
4. If adaptive or air suspension was disabled, re-enable it through vehicle settings

Verification

• Start the vehicle and verify no warning lights related to suspension or stability control appear
• With vehicle on level ground, bounce each corner of the front suspension to verify sway bar is functioning and no unusual noises are present
• Perform a low-speed test drive in a safe area, making gentle turns to verify proper handling and no clunking or rattling from the sway bar
• Inspect all connections for proper installation and check for any fluid leaks that may have occurred during work
• After 50-100 miles of driving, re-torque all sway bar mounting hardware to specification
• Verify proper wheel alignment if vehicle pulls to one side or steering wheel is off-center

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