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

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification
• Upper ball joint castle nut × 1 — Use OEM specification
• Upper control arm mounting bolts/nuts × 2 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes
4. Follow manufacturer procedures to disable high voltage system and apply lockout/tagout device
5. Loosen front wheel lug nuts while vehicle is on ground
6. Raise front of vehicle using manufacturer-specified lift points
7. Support vehicle securely on jack stands rated for at least 4 tons per side
8. Remove front wheel on side being serviced
9. Photograph suspension geometry and alignment marks if visible for reference

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the weight of the knuckle and suspension components. Raise jack just enough to take the load without compressing the suspension.
2. 2

   Remove upper ball joint cotter pin
   Locate the upper ball joint castle nut at the top of the steering knuckle. Remove and discard the cotter pin. Straighten the pin ends with pliers if necessary before extraction.
3. 3

   Loosen upper ball joint castle nut
   Loosen the castle nut on the upper ball joint but do not remove it completely yet. Leave it threaded on several turns to protect threads and catch the knuckle when the taper is broken.
4. 4

   Separate upper ball joint from knuckle
   Use a ball joint separator tool to break the taper between the upper ball joint stud and the knuckle. Position the tool according to manufacturer instructions and apply force until the joint releases. Once separated, remove the castle nut completely. Support the knuckle with the floor jack to prevent it from dropping.
5. 5

   Mark control arm position
   Before removing mounting hardware, mark the position of the upper control arm relative to its mounting bracket using a paint pen or scribe. This will help with initial alignment during reinstallation.
6. 6

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the upper control arm to the frame or subframe bracket. Support the control arm with one hand and remove the bolt completely. Note the orientation of any washers, spacers, or cam adjusters for reinstallation.
7. 7

   Remove rear control arm mounting bolt
   Remove the rear mounting bolt that secures the upper control arm to the frame or subframe bracket. The control arm should now be free. Carefully remove it from the vehicle, noting the routing and clearance around brake lines, sensors, and wiring.
8. 8

   Inspect mounting points and hardware
   Clean the mounting bolt holes in the frame brackets with a wire brush. Inspect bushings, mounting surfaces, and threads for damage, corrosion, or excessive wear. Replace fasteners if threads are damaged or if specified as one-time-use by manufacturer.
9. 9

   Install new upper control arm
   Position the new upper control arm into the mounting brackets, aligning it with the reference marks made during disassembly. Insert the front and rear mounting bolts, along with any washers, spacers, or cam adjusters in their original orientation. Thread bolts by hand but do not tighten yet.
10. 10

    Connect ball joint to knuckle
    Align the upper ball joint stud with the hole in the top of the steering knuckle. You may need to use the floor jack to raise or lower the knuckle to proper height. Install the castle nut and tighten by hand initially.
11. 11

    Torque mounting bolts
    With the suspension at normal ride height (supported by floor jack), torque the front and rear upper control arm mounting bolts to manufacturer specifications. If torque specifications are not available, consult factory service information before proceeding. These fasteners are critical to safety.
12. 12

    Torque ball joint castle nut
    Torque the upper ball joint castle nut to manufacturer specifications. If torque specifications are not available, consult factory service information. After torquing, align the next available castle slot with the cotter pin hole and install a new cotter pin. Bend cotter pin ends to secure.
13. 13

    Remove support and reinstall wheel
    Carefully lower and remove the floor jack from under the lower control arm. Reinstall the wheel and hand-tighten lug nuts in a star pattern. Lower vehicle to ground and torque lug nuts to specification (typically 150-180 ft-lbs for this vehicle, verify in owner's manual).

Reassembly

1. Ensure all fasteners are torqued to specification using proper sequence
2. Verify cotter pin is properly installed and secured in ball joint castle nut
3. Reconnect 12V auxiliary battery negative terminal
4. Follow manufacturer procedures to re-enable high voltage system and remove lockout/tagout device
5. Check for proper suspension movement and clearance before driving

Verification

• Visually inspect all fasteners to confirm proper installation and torque
• Verify upper ball joint stud is properly seated in knuckle and secured with cotter pin
• Check for adequate clearance between control arm and all surrounding components through full suspension travel
• Test drive vehicle at low speed in a safe area and listen for unusual noises from suspension
• Have wheel alignment performed immediately at a qualified shop with equipment capable of servicing commercial electric vehicles
• After alignment, verify steering wheel is centered and vehicle tracks straight
• Re-torque all fasteners after 50-100 miles of driving

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