Wheel Bearing Hub - Front

This procedure covers the removal and replacement of the front wheel bearing hub assembly on a 2024 Rivian EDV 500 dual motor AWD electric delivery vehicle.

Warnings

Tools required

Parts

• Front wheel bearing hub assembly × 1 — Use OEM Rivian specification
• Axle nut cotter pin × 1 — Use OEM specification
• Hub mounting bolts (if reuse not recommended) × 4 — Use OEM specification

Preparation

1. Verify vehicle is powered off and in Park mode with parking brake released
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on the ground (do not remove)
4. With vehicle still on the ground, use breaker bar to break loose the front axle nut (250 Nm) - do not remove completely yet
5. Lift front of vehicle using designated lift points and secure on jack stands rated for electric vehicle weight
6. Remove front wheel completely
7. Clean work area around hub assembly and suspension components

Procedure

1. 1

   Remove axle nut and disconnect ABS sensor
   Remove the cotter pin from the axle nut using pliers or a cotter pin removal tool. Completely remove the axle nut (already loosened during preparation). Locate the ABS wheel speed sensor connector near the hub assembly and disconnect it. Remove the ABS sensor mounting bolt and carefully extract the sensor from the hub, noting its orientation.
   ⚠The ABS sensor is fragile. Do not pull on the wiring harness and avoid dropping the sensor or exposing it to magnetic materials.
   Torque spec

   ABS Sensor Bolt10 Nm (7 lb-ft)
2. 2

   Remove brake caliper assembly
   Remove the two brake caliper bracket bolts using a 19mm socket. Carefully slide the entire caliper and bracket assembly off the rotor. Support the caliper with mechanics wire or a suitable hanger to prevent strain on the brake hose. Do not disconnect the brake hose unless replacement is required.
   Torque spec

   Brake Caliper Bracket Bolts120 Nm (88 lb-ft)
3. 3

   Remove brake rotor
   If present, remove any retaining screws or clips securing the brake rotor to the hub. Slide the brake rotor off the hub studs. If the rotor is seized due to corrosion, tap gently with a rubber mallet around the hat section while rotating. Do not strike the friction surface.
4. 4

   Disconnect outer tie rod end
   Remove the cotter pin and castle nut from the outer tie rod end ball joint. Use a ball joint separator or pickle fork to separate the tie rod end from the steering knuckle. Avoid damaging the ball joint boot if the tie rod will be reused.
   ⚠Do not hammer directly on tie rod threads. Use a proper ball joint separator tool to avoid damage.
5. 5

   Disconnect lower ball joint or control arm
   Depending on suspension configuration, either remove the bolts securing the lower ball joint to the knuckle, or disconnect the lower control arm ball joint from the steering knuckle. This will allow the knuckle to pivot and provide access to remove the drive axle from the hub.
6. 6

   Separate drive axle from hub
   Pull the steering knuckle assembly outward while supporting the drive axle. Carefully slide the drive axle splines out of the hub bore. If the axle is stuck, use a soft-faced hammer to tap the end of the axle shaft while applying outward pressure to the knuckle. Do not allow the axle to hang unsupported; support it with wire or rest it on the lower control arm.
   ⚠The drive axle CV joint can be damaged if bent excessively. Support the axle to prevent over-extension of the inner CV joint.
7. 7

   Remove hub mounting bolts
   From the back side of the steering knuckle, locate the four wheel bearing hub mounting bolts. These bolts secure the hub assembly to the knuckle. Remove all four bolts using a 19mm socket. Note: These bolts may have threadlocker applied from the factory.
   Torque spec

   Wheel Bearing Hub Bolts110 Nm (81 lb-ft)
8. 8

   Extract old hub assembly
   Pull the hub assembly out of the steering knuckle from the front side. If the hub is seized in the knuckle bore, use a hub puller or slide hammer with appropriate adapters to extract it. Clean the knuckle bore thoroughly with a wire brush, removing all corrosion, old threadlocker residue, and debris.
   ℹ️Inspect the knuckle bore for damage, scoring, or cracks. Any damage to the knuckle may require knuckle replacement.
9. 9

   Prepare and install new hub assembly
   Clean the new hub assembly mounting surface and the ABS sensor opening. Apply a light coat of anti-seize to the outer diameter of the new hub where it contacts the knuckle bore (avoid getting anti-seize in the bearing or on the ABS sensor). Insert the new hub assembly into the knuckle from the front side, ensuring it is fully seated and properly aligned.
10. 10

    Install and torque hub mounting bolts
    Apply medium-strength threadlocker to the threads of the four hub mounting bolts as specified by manufacturer. Insert all four bolts from the rear of the knuckle and hand-tighten. Torque the hub mounting bolts to 110 Nm (81 lb-ft) in a criss-cross pattern to ensure even seating of the hub assembly.
    ⚠Use the correct threadlocker type and torque sequence to prevent hub movement or bolt failure.
    Torque spec

    Wheel Bearing Hub Bolts110 Nm (81 lb-ft)
11. 11

    Reinstall drive axle into hub
    Align the drive axle splines with the hub bore. Push the knuckle assembly inward while guiding the axle splines through the hub. Ensure the axle is fully seated. Install the axle nut and hand-tighten it to hold the axle in position (final torque will be applied later).
12. 12

    Reconnect suspension and steering components
    Reconnect the lower ball joint or control arm to the steering knuckle and tighten bolts to specification. Reconnect the outer tie rod end to the steering knuckle, install the castle nut, and torque to specification. Install a new cotter pin through the castle nut and tie rod stud.
13. 13

    Install ABS sensor
    Clean the ABS sensor and its mounting bore in the hub. Inspect the sensor tip for damage or debris. Carefully insert the ABS sensor into the hub bore in the correct orientation. Install the ABS sensor mounting bolt and torque to 10 Nm (7 lb-ft). Do not overtighten as this can damage the sensor or mounting boss. Reconnect the ABS sensor electrical connector.
    ⚠The ABS sensor bolt is intentionally low torque. Overtightening will strip the aluminum threads in the hub.
    Torque spec

    ABS Sensor Bolt10 Nm (7 lb-ft)
14. 14

    Reinstall brake rotor and caliper
    Slide the brake rotor onto the hub studs and install any retaining screws or clips if present. Position the brake caliper and bracket assembly over the rotor. Install the caliper bracket bolts and torque to 120 Nm (88 lb-ft).
    Torque spec

    Brake Caliper Bracket Bolts120 Nm (88 lb-ft)
15. 15

    Final torque axle nut
    Install the front wheel and lug nuts, hand-tightening only. Lower the vehicle to the ground so the wheel is in contact but still supported slightly by the jack. Using a torque wrench, torque the axle nut to 250 Nm (184 lb-ft). Install a new cotter pin through the axle nut and castle slots, bending the pin ends to secure it. Fully lower the vehicle and torque the wheel lug nuts to specification in a star pattern. Remove jack stands and chocks.
    ⚠The axle nut must be torqued with the vehicle on the ground or the hub will rotate, preventing accurate torque measurement.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)

Reassembly

1. All fasteners have been torqued to specification during the procedure
2. Ensure new cotter pin is properly installed and secured on axle nut
3. Verify ABS sensor connector is fully seated and locked
4. Verify brake caliper is properly positioned and brake hose is not twisted or strained

Verification

• Start vehicle and verify no ABS warning lights are illuminated on the instrument cluster
• Perform a low-speed test drive (under 10 mph) in a safe area and verify no unusual noises from the hub area
• Test brake function at low speed to ensure proper operation
• If available, use a diagnostic scan tool to verify the front ABS wheel speed sensor is reading correctly and matches the opposite side
• After test drive, re-check axle nut torque to ensure it has not loosened
• Inspect for any fluid leaks around brake components
• Schedule a wheel alignment check as suspension components were disconnected

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