Wheel Bearing - Press-In Front

This procedure covers the removal and replacement of a press-in front wheel bearing on a 2024 Rivian EDV 500 electric delivery van, requiring hub removal and bearing press-out/press-in operations.

Warnings

Tools required

Parts

• Front wheel bearing assembly (press-in type) × 1 — Use OEM specification
• Wheel hub seal (inner and/or outer as applicable) × 1 — Use OEM specification
• Axle hub nut × 1 — Single-use fastener, replace each time
• Tie rod end cotter pin or lock nut × 1 — If equipped
• Ball joint pinch bolt × 1 — Use OEM specification if reuse not permitted
• Anti-seize compound × 1 — High-temperature rated
• Brake parts cleaner × 1 — Non-chlorinated recommended

Preparation

1. Park vehicle on level surface and engage parking brake
2. Perform high-voltage system shutdown per Rivian service manual procedure and verify system is de-energized
3. Loosen front axle hub nut while vehicle is on ground with wheels chocked and assistant applying brakes
4. Raise vehicle on lift or jack stands at manufacturer-specified lift points
5. Remove front wheel and tire assembly from affected side
6. Clean wheel hub area, suspension components, and fasteners with brake parts cleaner and wire brush
7. Apply penetrating oil to all fasteners to be removed and allow to soak
8. Take photographs of brake routing, ABS sensor routing, and suspension alignment for reference during reassembly

Procedure

1. 1

   Remove brake caliper and rotor
   Remove brake caliper mounting bolts and carefully lift caliper off rotor. Hang caliper from suspension using caliper hanger or mechanic's wire - do not allow caliper to hang by brake hose. Remove caliper bracket mounting bolts and remove bracket. Slide brake rotor off hub studs. If rotor is stuck, use rotor puller screws in threaded holes if provided.
2. 2

   Disconnect ABS wheel speed sensor
   Locate ABS wheel speed sensor connector near the wheel hub or inner fender. Disconnect electrical connector by releasing locking tab. Remove sensor mounting bolt and carefully extract sensor from hub or knuckle. Note routing of sensor wire for reinstallation. Inspect sensor tip for damage or debris.
3. 3

   Remove axle hub nut
   Fully remove the front axle hub nut that was previously loosened. This nut is single-use and must be replaced. Check if nut has locking tab that needs to be bent straight before removal. Keep axle supported and note if there are washers or spacers behind the nut.
4. 4

   Disconnect tie rod end
   Remove tie rod end castle nut (after removing cotter pin if equipped) or lock nut from steering knuckle. Use tie rod end separator tool to break taper connection between tie rod end and knuckle. Do not use excessive force with pickle fork as this may damage tie rod end boot. Count and record number of threads visible on tie rod for alignment reference.
   ⚠Steering alignment will be affected. Record tie rod position and plan for professional alignment after repair.
5. 5

   Separate ball joint from knuckle
   Remove lower ball joint pinch bolt or castle nut (depending on Rivian EDV design) securing ball joint to steering knuckle. Use ball joint separator if needed to break taper. Support lower control arm with jack stand if necessary. Once separated, carefully pivot knuckle outward to create working clearance.
6. 6

   Remove hub and knuckle assembly
   Pull outward on steering knuckle while pushing axle shaft inward to disengage splines from hub. If axle is stuck in hub, use soft-face mallet to tap end of axle shaft. Remove strut-to-knuckle bolts (typically 2 bolts). Remove steering knuckle with hub still attached from vehicle. Place assembly on clean workbench for disassembly.
   ⚠Support axle shaft after knuckle removal to prevent damage to CV joint or differential seals.
7. 7

   Remove hub from knuckle
   Secure steering knuckle in vise using padded jaws or protective material. Remove hub mounting bolts if present, or prepare for press-out operation. Use hydraulic press with appropriate adapters to press hub out of bearing inner race. Press only on hub, not on bearing components. If hub is severely stuck, apply heat to knuckle (not exceeding 300°F) to aid removal.
8. 8

   Remove old bearing from knuckle
   Remove bearing retaining snap ring from knuckle bore using snap ring pliers. Position knuckle in hydraulic press with support fixture that contacts knuckle face evenly around bearing bore. Use bearing press adapter that contacts only the outer race of bearing. Press bearing completely out of knuckle bore. Remove inner and outer seals.
   ⚠Never press against bearing rolling elements or cage. Press only on races using correct adapters to prevent press equipment damage or personal injury.
9. 9

   Prepare knuckle for new bearing
   Thoroughly clean bearing bore in knuckle using brake parts cleaner and lint-free cloth. Inspect bore for damage, scoring, or corrosion. Use fine emery cloth to remove minor imperfections if needed. Measure bearing bore diameter with caliper to verify it is within specification and not worn oversize. Clean snap ring groove completely.
10. 10

    Install new bearing into knuckle
    Verify new bearing matches old bearing dimensions and specifications. If using bearing race freezer or dry ice, cool new bearing for 15-20 minutes to aid installation (optional but recommended). Apply thin film of anti-seize to knuckle bore outer edge only - do not contaminate bearing. Position knuckle in press with proper support. Align bearing squarely in bore. Use press adapter that contacts only outer race. Press bearing until fully seated against shoulder in bore. Verify bearing is seated evenly all around.
    ⚠️Bearing must be pressed perfectly square. Cocked bearing will bind, create runout, and fail prematurely.
11. 11

    Install snap ring and seals
    Install bearing retaining snap ring in knuckle groove, ensuring it is fully seated in groove around entire circumference. Install new inner and outer hub seals using appropriate seal driver. Drive seals squarely until seated flush or to specification depth. Apply small amount of brake-safe grease to seal lips.
12. 12

    Press hub into new bearing
    Clean hub shaft and splines thoroughly. Inspect hub for wear, cracks, or damage. Apply anti-seize to hub outer surface that contacts seal. Position knuckle/bearing assembly in press with support under knuckle. Align hub with bearing bore. Press hub into bearing inner race using adapter that contacts only the inner race or hub shoulder - never press on hub studs. Press until hub is fully seated. Verify hub rotates smoothly with slight drag from new bearing.
13. 13

    Verify bearing installation
    Check that hub rotates without binding or excessive noise. Check for any axial play by attempting to move hub in and out - there should be no perceptible movement. If dial indicator is available, check hub face runout (should be less than 0.003 inches typically). Verify snap ring is secure and seals are properly seated.
14. 14

    Reinstall knuckle and hub assembly
    Position assembled knuckle/hub onto vehicle, aligning strut mounting holes and ball joint location. Install strut-to-knuckle bolts finger tight. Reconnect lower ball joint to knuckle and install pinch bolt or castle nut. Align hub splines with axle shaft and push knuckle inward to fully engage splines. Install new axle hub nut finger tight. Reconnect tie rod end to knuckle and install castle nut or lock nut.
15. 15

    Reinstall brake components and finalize
    Reinstall ABS wheel speed sensor into hub or knuckle, ensuring sensor tip is clean and properly seated. Connect sensor electrical connector. Install brake rotor onto hub. Install caliper bracket and torque mounting bolts per specification. Install brake caliper and torque mounting bolts per specification. Install wheel and tire assembly, torquing lug nuts in star pattern. Lower vehicle enough to prevent wheel rotation. Apply brakes and torque axle hub nut to specification (typically 150-200 ft-lbs for vehicles in this class, verify with Rivian documentation). Stake or lock axle nut per design. Torque all suspension fasteners per Rivian specifications. Torque wheel lug nuts to final specification in star pattern.
    ⚠All suspension and steering fasteners must be torqued with vehicle at ride height or with suspension loaded per manufacturer procedure.

Reassembly

1. All fasteners must be torqued to Rivian specifications - consult service manual for exact values as none were provided in database
2. Axle hub nut is critical for bearing preload and must be torqued accurately and locked properly
3. Ensure all electrical connectors for ABS sensors are fully seated and locked
4. Verify brake caliper slides and pins are lubricated and functioning properly before road use
5. Double-check that no tools, parts, or hardware have been left in wheel well or suspension area

Verification

• Pump brake pedal several times until firm before moving vehicle
• Perform high-voltage system re-initialization per Rivian procedure if required
• Test drive vehicle at low speed in safe area, listening for any abnormal noises from wheel bearing area
• Check for vibration, pulling, or unusual steering feedback during test drive
• Verify ABS warning light is off and system self-test passes
• Recheck wheel lug nut torque after 50-100 miles of driving
• Schedule four-wheel alignment as soon as possible after repair to verify steering and suspension geometry
• Monitor bearing area for signs of heat, noise, or play during first several hundred miles of operation

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