This procedure covers the removal and replacement of the front upper control arm on a 2024 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Front upper control arm assembly × 1 — Use OEM specification
• Upper control arm mounting bolts × 2 — Use OEM specification
• Upper ball joint nut × 1 — Use OEM specification
• Alignment shims (if applicable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery negative terminal
4. Verify high voltage system is disabled (consult service manual for proper lockout procedure)
5. Loosen front wheel lug nuts while vehicle is on ground
6. Raise vehicle on lift or jack stands at manufacturer-specified lift points
7. Remove front wheel on affected side
8. Photograph or mark alignment cam positions if control arm has adjustable cam bolts

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the suspension assembly. Raise jack just enough to contact the control arm without lifting the vehicle. This prevents the suspension from dropping when the upper control arm is disconnected.
2. 2

   Remove wheel speed sensor clearance
   If the wheel speed sensor wiring or brake hose is routed near the upper control arm, carefully move or secure it away from the work area. Use a zip tie or wire to temporarily secure these components to prevent damage during removal.
3. 3

   Remove upper ball joint castle nut
   Remove the cotter pin from the upper ball joint castle nut. Using an 18mm socket, remove the castle nut from the ball joint stud. Do not allow the ball joint stud to spin - if necessary, use a hex key in the top of the stud to hold it steady.
   ⚠The ball joint taper is under load. The knuckle may shift suddenly when the nut is removed.
4. 4

   Separate ball joint from knuckle
   Use a ball joint separator tool or pickle fork to separate the upper ball joint stud from the steering knuckle. Insert the tool between the control arm and knuckle, then strike or apply pressure to break the taper fit. If using a pickle fork, be aware this may damage the ball joint boot if the control arm were to be reused.
   ⚠Support the knuckle assembly as it may drop when the ball joint separates.
5. 5

   Mark control arm orientation
   Before removing the control arm mounting bolts, mark the orientation of the control arm relative to the frame mounting points. Note the position of any alignment shims or eccentric cams. Take photos for reference during installation.
6. 6

   Remove front frame mounting bolt
   Using a 21mm socket and breaker bar, remove the front upper control arm mounting bolt that attaches the control arm to the frame or subframe. Support the control arm as the bolt is removed. Note any alignment shims present and keep them in order for reinstallation.
7. 7

   Remove rear frame mounting bolt
   Remove the rear upper control arm mounting bolt using a 21mm socket. The control arm should now be free to remove. If the control arm binds, verify both mounting bolts are completely removed and the ball joint is fully separated.
8. 8

   Remove control arm from vehicle
   Carefully maneuver the upper control arm out of the suspension assembly. Note the routing path for reinstallation. Inspect the removed control arm for the cause of failure - bent arms, damaged bushings, or worn ball joints.
9. 9

   Clean mounting surfaces
   Use a wire brush to clean the frame mounting bolt holes and surrounding surfaces. Remove any corrosion, dirt, or debris. Inspect the frame mounting points for cracks, elongated bolt holes, or damage. Clean the ball joint taper seat in the steering knuckle.
10. 10

    Install new upper control arm
    Position the new upper control arm into the frame mounting points. Insert the ball joint stud into the steering knuckle taper. Install alignment shims in their original positions. Start both frame mounting bolts by hand, but do not fully tighten yet. Apply anti-seize to bolt threads if desired.
11. 11

    Install ball joint nut
    Install the new castle nut onto the upper ball joint stud. Tighten the nut to draw the ball joint taper fully into the knuckle seat. Tighten until the next castle slot aligns with the cotter pin hole, then install a new cotter pin. Bend the cotter pin ends to secure.
12. 12

    Torque frame mounting bolts
    With the suspension at ride height (supported by the floor jack under the lower control arm), torque the front and rear upper control arm mounting bolts. Since no torque specifications are provided in the database, consult the factory service manual for proper torque values. Apply thread locker if specified by manufacturer. Tighten bolts in the sequence specified in the service manual.
    ℹ️Control arm mounting bolts must be torqued at ride height to prevent bushing bind and premature wear.
13. 13

    Remove floor jack and reinstall wheel
    Carefully lower and remove the floor jack from under the lower control arm. Inspect the suspension for proper positioning and clearance. Reinstall the wheel and hand-tighten the lug nuts in a star pattern.
14. 14

    Lower vehicle and final torque
    Lower the vehicle to the ground. Torque the wheel lug nuts to specification in a star pattern. Reconnect the 12V battery negative terminal and re-enable the high voltage system per manufacturer procedures.

Reassembly

1. Ensure all fasteners are torqued to specification (consult factory service manual for specific values not listed in database)
2. Verify cotter pin is properly installed and secured in ball joint castle nut
3. Check that no wiring harnesses or brake lines are pinched or interfering with suspension travel
4. Confirm wheel speed sensor is properly positioned and secured

Verification

• Perform a visual inspection of all mounting points and fasteners
• Bounce the front suspension to ensure proper operation and no unusual noises
• Check for adequate clearance between control arm and surrounding components through full suspension travel
• Test drive at low speed in a safe area to verify no vibration or noise
• Schedule immediate four-wheel alignment at qualified facility - alignment is mandatory after control arm replacement
• After alignment, verify steering wheel is centered and vehicle tracks straight

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