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2024 RIVIAN EDV 500
Dual Motor AWD (EDV)•FWD•ev
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Repairs273Labor323Torque97Fluid5DTC726Battery1Maintenance0Recalls0
suspension

Front Suspension Rebuild

for 2024 Rivian EDV 500 Dual Motor AWD (EDV) · FWD
Editorial review:Chris Hackleman — Master Technician · 20+ years
Difficulty
Expert
Time
7.5 h
Tools
17
Steps
21
✓Expert-verified. Personally reviewed and approved by OLP's master technicians (Chris Hackleman — 20+ years each). Always follow the vehicle's factory service information and torque specs.

Complete removal and replacement of all front suspension components including control arms, ball joints, tie rods, stabilizer links, struts, and related hardware for the Rivian EDV 500 commercial delivery van.

Warnings

⚠️This vehicle contains high-voltage electrical systems. Ensure 12V and high-voltage systems are properly disconnected per Rivian service procedures before beginning work.
⚠️Spring compressors must be properly installed and tightened evenly to prevent catastrophic spring release which can cause severe injury or death.
⚠Vehicle must be professionally aligned after suspension rebuild to prevent premature tire wear and unsafe handling characteristics.
⚠Due to EDV 500 commercial payload capacity, suspension components are under significant load. Ensure vehicle is properly supported on jack stands rated for commercial vehicle weight.
ℹ️Mark or photograph existing tie rod positions before removal to provide approximate alignment starting point during reassembly.

Tools required

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Parts

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Preparation

  1. Park vehicle on level surface and engage parking brake
  2. Place wheel chocks behind rear wheels
  3. Disconnect 12V battery negative terminal using battery disconnect tool and wait 5 minutes for system capacitors to discharge
  4. Verify high-voltage system is in service mode per Rivian EDV service manual procedures
  5. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
  6. Raise front of vehicle using floor jack at manufacturer-specified lift points
  7. Support vehicle on jack stands placed at frame rails, ensuring minimum 18 inches of clearance
  8. Remove both front wheels completely and set aside
  9. Apply penetrating oil to all suspension fasteners and allow to soak for 15-20 minutes
  10. Mark tie rod thread position with paint marker or measure exposed threads for reference
  11. Take reference photos of suspension geometry from multiple angles for reassembly verification

Procedure

  1. 1
    Remove stabilizer bar links
    Working on both sides, use a wrench to hold the ball stud while loosening the upper and lower stabilizer link nuts. Remove nuts completely and disconnect links from both the stabilizer bar and lower control arm. Inspect rubber boots for tears and note any binding in ball joints.
  2. 2
    Disconnect outer tie rod ends
    Remove cotter pins from outer tie rod castle nuts. Using appropriate wrench, loosen and remove castle nuts. Use tie rod end puller to separate outer tie rod from steering knuckle. Do not strike with hammer as this can damage steering components. Count and record exposed threads on tie rod for reassembly reference.
  3. 3
    Remove brake caliper and rotor
    Remove brake caliper mounting bolts and carefully hang caliper from frame using wire or zip ties - do not allow caliper to hang by brake hose. Remove brake rotor retaining screws if equipped and slide rotor off hub. This provides clearance for control arm and knuckle removal.
  4. 4
    Disconnect ABS sensor and brake line brackets
    Unplug ABS wheel speed sensor connector at harness. Remove any brake line mounting brackets attached to control arm or knuckle. Carefully route wiring clear of work area to prevent damage during component removal.
  5. 5
    Remove upper ball joint connection
    Remove cotter pin and castle nut from upper ball joint. Use ball joint separator tool to disconnect upper ball joint from steering knuckle. Apply steady pressure with separator while tapping knuckle boss with brass hammer to break taper fit. Support knuckle to prevent stress on CV axle.
  6. 6
    Remove lower ball joint connection
    Remove cotter pin and castle nut from lower ball joint. Use ball joint separator to disconnect lower ball joint from steering knuckle. Once separated, carefully lower knuckle and support assembly, being mindful not to overextend CV axle or damage ABS tone ring.
  7. 7
    Remove strut assembly upper mount
    Access strut tower under hood and remove protective cover if equipped. While supporting strut from below, remove three upper strut mount nuts. Hold strut shaft with wrench to prevent spinning while removing center nut. Do not allow strut assembly to drop suddenly.
  8. 8
    Remove strut assembly from vehicle
    With upper mount disconnected, guide strut assembly down and out from wheel well. Maneuver carefully past CV axle and brake components. Place strut assembly on workbench in safe location for disassembly if rebuilding or replacing individual components.
  9. 9
    Remove upper control arm
    Locate upper control arm frame mounting bolts. Support control arm with jack or by hand to prevent dropping. Remove front and rear mounting bolts securing upper control arm to frame. Carefully extract control arm from mounting position, noting orientation of any eccentric washers or alignment cams for reassembly.
  10. 10
    Remove lower control arm
    Support lower control arm with floor jack. Remove rear mounting bolt first, then front pivot bolt while controlling descent of control arm. The EDV 500 uses heavy-duty control arms due to commercial payload rating - control arm will be heavy. Inspect frame mounting points for damage or corrosion.
  11. 11
    Remove inner tie rods and steering rack boots
    Loosen jam nuts on inner tie rods using appropriately sized wrench. Unscrew outer tie rod ends and set aside with thread count recorded. Remove inner tie rod from steering rack using inner tie rod socket or adjustable wrench. Remove steering rack boots if replacing. Inspect steering rack for leaks or damage.
  12. 12
    Remove stabilizer bar
    Remove stabilizer bar mounting bracket bolts from frame on both sides. Note orientation of brackets and bushings. Carefully lower stabilizer bar from vehicle, maneuvering around subframe and other components. Inspect bushings for cracking, tearing, or compression set indicating replacement needed.
  13. 13
    Install new stabilizer bar and bushings
    Install new bushings onto stabilizer bar with slit facing correct direction per service manual. Position stabilizer bar in vehicle and loosely install mounting brackets. Ensure bar is centered with equal spacing on both sides before tightening bracket bolts. Apply thin layer of silicone grease to bushing interior to reduce squeaking.
  14. 14
    Install lower control arms
    Position new lower control arms with bushings pre-installed. Insert front pivot bolt first, then rear mounting bolt. Start threads on both bolts but do not torque yet - suspension must be at ride height before final torquing. Verify control arm moves freely through full range of motion without binding.
  15. 15
    Install upper control arms
    Position new upper control arms ensuring proper orientation and alignment cam/eccentric washer placement matches original position. Install mounting bolts and start threads. Do not fully torque at this time. Verify ball joint stud is properly positioned for knuckle installation.
  16. 16
    Install strut assemblies
    If struts were disassembled, reassemble with new components using spring compressor to safely compress springs. Guide strut assembly into wheel well and position upper mount to strut tower. Install upper mount nuts and torque center nut while holding shaft. Position lower strut mount to control arm location.
  17. 17
    Reconnect steering knuckle and ball joints
    Position steering knuckle onto lower ball joint stud and install new castle nut. Connect upper ball joint stud to knuckle and install new castle nut. Torque both castle nuts to specification and install new cotter pins, advancing nuts only to align cotter pin holes. Ensure ball joint boots are not torn or pinched.
  18. 18
    Install inner and outer tie rods
    Install new inner tie rods to steering rack with thread-locking compound, torquing to specification. Install new steering rack boots if replaced. Thread outer tie rod ends onto inner tie rods to previously recorded thread count. Connect outer tie rod to knuckle, install castle nut, and insert new cotter pin.
  19. 19
    Install stabilizer bar links
    Connect new stabilizer bar links to control arms and stabilizer bar. Install new nuts and torque to specification while holding ball stud with wrench. Ensure rubber boots are properly seated and not damaged during installation.
  20. 20
    Reinstall brake and wheel components
    Reinstall brake rotors and torque rotor screws if equipped. Position brake calipers over rotors and install caliper mounting bolts with thread-locking compound, torquing to specification. Reconnect ABS sensors and secure all brake line brackets. Verify brake hoses are not twisted or kinked.
  21. 21
    Load suspension and perform final torquing
    Install wheels and lower vehicle until suspension is at normal ride height (tires touching ground but not supporting full weight). This is critical for proper bushing orientation. Torque all control arm mounting bolts, strut bolts, and other suspension fasteners to manufacturer specifications with vehicle at ride height. Then raise vehicle to remove jack stands.

Reassembly

  1. Install wheels and torque lug nuts in star pattern to manufacturer specification
  2. Lower vehicle completely to ground
  3. Reconnect 12V battery and clear any diagnostic codes using Rivian service tool
  4. Pump brake pedal several times to restore brake pressure before moving vehicle
  5. Test all electrical systems including ABS sensors to ensure proper connection
  6. Perform brake system check and verify proper operation before road test

Verification

  • Transport vehicle to professional alignment shop immediately - EDV 500 requires commercial-grade alignment equipment and Rivian-specific specifications
  • Perform complete four-wheel alignment including camber, caster, toe, and steering angle sensor calibration
  • Road test vehicle at various speeds up to 45 mph, verifying straight-line tracking, no pulling, and no unusual noises
  • Verify steering returns to center properly after turns
  • Re-torque all suspension fasteners after 50-100 miles of driving
  • Inspect all connections for proper seating and verify no fluid leaks from steering rack or differential
  • Verify tire wear patterns are even after 500 miles and re-check alignment if irregular wear appears
  • Test regenerative braking system functions properly with no ABS warning lights

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

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