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

Warnings

Tools required

Parts

• Rear upper control arm assembly × 1 — Use OEM specification
• Control arm mounting bolts × 2 — Use OEM specification if not reusing
• Ball joint castle nut × 1 — Use OEM specification if not reusing
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks at front wheels
3. Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
4. Loosen rear wheel lug nuts while vehicle is on ground
5. Raise rear of vehicle using floor jack at designated rear lift point
6. Support vehicle with jack stands under manufacturer-specified jacking points
7. Remove rear wheel on side being serviced
8. Spray penetrating oil on all control arm fasteners and allow to soak for 10 minutes

Procedure

1. 1

   Mark alignment reference
   Before removing any fasteners, use a paint pen or marker to mark the relationship between the upper control arm and its mounting points. This provides a reference for initial alignment during reinstallation and can reduce post-repair alignment time.
2. 2

   Support suspension assembly
   Position a floor jack under the rear knuckle or lower control arm to support the suspension at approximately ride height. This relieves tension on the upper control arm and prevents the suspension from dropping when the arm is disconnected.
3. 3

   Remove upper ball joint cotter pin and castle nut
   Locate the upper ball joint where it connects to the rear knuckle. Remove the cotter pin from the castle nut, then use a 21mm socket to remove the castle nut. Do not fully remove the nut until the ball joint taper is broken in the next step to prevent sudden separation.
4. 4

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, break the taper fit between the upper ball joint and the knuckle. Position the tool properly to avoid damage to the ball joint boot if reusing the control arm. Once the taper is broken, remove the castle nut completely and separate the ball joint from the knuckle.
5. 5

   Remove front control arm mounting bolt
   Locate the forward mounting point where the control arm attaches to the chassis or subframe. Use a 19mm or 21mm socket (depending on actual fastener size) to remove the mounting bolt. Support the control arm while removing this bolt to prevent it from dropping. Note the orientation of any washers, bushings, or spacers for reinstallation.
6. 6

   Remove rear control arm mounting bolt
   Locate the rear mounting point where the control arm attaches to the chassis or subframe. Remove this mounting bolt using the appropriate socket. The control arm should now be free from the vehicle. Carefully remove the control arm assembly and inspect all bushings and mounting points for wear or damage.
7. 7

   Inspect mounting points and prepare for installation
   Clean all mounting bolt holes in the chassis and knuckle using a wire brush. Inspect the ball joint mounting taper in the knuckle for damage or distortion. Check that the suspension mounting brackets are not bent or cracked. Apply a light coat of anti-seize to bolt threads unless thread locker will be used.
8. 8

   Install new upper control arm
   Position the new upper control arm into place, aligning it with your reference marks from Step 1. Insert the rear mounting bolt first and thread it by hand to hold the arm in position. Then insert the front mounting bolt and thread by hand. Do not fully tighten either bolt yet; leave them finger-tight to allow for alignment adjustment.
9. 9

   Connect ball joint to knuckle
   Ensure the ball joint taper and knuckle bore are clean and dry. Align the upper ball joint with the knuckle and use the floor jack to raise the knuckle into position if needed. Insert the ball joint stud into the knuckle taper and install the castle nut. Thread the nut until it seats firmly against the knuckle.
10. 10

    Torque ball joint castle nut
    Torque the ball joint castle nut to manufacturer specification. If specification is not available, typical value for this vehicle class is 50-70 ft-lb. After torquing, continue tightening only as much as needed to align the next castle slot with the cotter pin hole. Never loosen the nut to align the cotter pin hole. Install a new cotter pin and bend the ends to secure.
11. 11

    Torque control arm mounting bolts
    With the suspension at ride height (supported by floor jack), torque the front and rear control arm mounting bolts to manufacturer specification. Torque these bolts with the suspension loaded to prevent premature bushing wear. If specifications are not available, typical values for this application are 120-150 ft-lb. Apply medium-strength thread locker if specified by manufacturer.
12. 12

    Remove jack support and reinstall wheel
    Carefully lower and remove the floor jack from under the suspension assembly. Reinstall the rear wheel and thread all lug nuts by hand. Lower the vehicle until the tire just contacts the ground, then torque lug nuts in a star pattern to manufacturer specification (typically 150-180 ft-lb for this vehicle).

Reassembly

1. Ensure all suspension fasteners are torqued to specification with suspension at ride height
2. Verify ball joint cotter pin is properly installed and secured
3. Remove jack stands and fully lower vehicle to ground
4. Reconnect 12V battery negative terminal
5. Start vehicle and verify no suspension warning lights appear on dashboard

Verification

• Perform visual inspection of all control arm mounting points to ensure proper installation and torque
• Bounce the rear suspension and listen for any unusual noises indicating loose fasteners or improper installation
• Test drive vehicle at low speed in a safe area, checking for abnormal handling, pulling, or noises
• Schedule four-wheel alignment as soon as possible after repair to prevent premature tire wear and ensure proper handling characteristics

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