This procedure covers the removal and replacement of the front ABS wheel speed sensor on a 2025 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Front ABS wheel speed sensor × 1 — Use OEM specification
• Sensor mounting bolt × 1 — Use OEM specification if not reusable

Preparation

1. Connect scan tool and retrieve any stored ABS diagnostic trouble codes, noting the specific wheel sensor circuit affected
2. Park vehicle on level surface and engage parking brake
3. Disconnect the 12V auxiliary battery negative terminal and wait 2 minutes
4. Raise and support the front of the vehicle on jack stands at the manufacturer-approved lift points
5. Remove the front wheel on the affected side
6. Verify you have the correct replacement sensor for left or right side as they may differ

Procedure

1. 1

   Access the wheel speed sensor
   Remove any wheel well liner clips or fasteners obstructing access to the sensor mounting area on the steering knuckle. The sensor is typically mounted on the rear side of the knuckle near the CV axle. On the EDV 500, you may need to partially fold back the inner fender liner to access the sensor connector.
2. 2

   Disconnect the sensor electrical connector
   Locate the wheel speed sensor connector approximately 12-18 inches from the sensor body along the harness routing. Press the connector lock tab and carefully separate the connector halves. Inspect the connector terminals for corrosion or damage and clean with electrical contact cleaner if needed.
3. 3

   Release the wiring harness routing clips
   Trace the sensor wiring from the connector to the sensor body and release any routing clips or brackets securing the harness to the suspension components or chassis. Note the exact routing path for reinstallation. Use a pick tool to release press-fit clips without breaking them.
4. 4

   Remove the sensor mounting bolt
   Using a 10mm socket, carefully remove the wheel speed sensor mounting bolt from the steering knuckle. If the bolt is corroded or difficult to remove, apply penetrating oil and allow it to soak for several minutes. Do not use excessive force which could damage the knuckle threads.
5. 5

   Extract the wheel speed sensor
   Gently pull the sensor straight out of the steering knuckle bore. If the sensor is stuck due to corrosion, carefully work it back and forth while pulling. Do not pry against the knuckle or use the sensor body as a lever point. If severely corroded, apply penetrating oil around the sensor body and allow it to penetrate.
6. 6

   Clean the sensor mounting bore
   Use a wire brush to thoroughly clean the sensor mounting bore in the steering knuckle, removing all rust, corrosion, and debris. The bore must be clean to ensure proper sensor alignment and air gap to the tone ring. Wipe clean with a lint-free cloth.
7. 7

   Inspect the tone ring
   Visually inspect the reluctor/tone ring on the CV axle or hub assembly for damage, missing teeth, cracks, or excessive rust buildup. Clean the tone ring surface with a wire brush if necessary. Any damage to the tone ring will require hub or axle replacement as these are typically non-serviceable separately.
8. 8

   Prepare the new sensor
   Remove the new sensor from its protective packaging. Inspect the sensor tip for any metal debris or contamination from manufacturing. Ensure the sensor O-ring or seal is properly seated in its groove. Do not apply grease or lubricant to the sensor tip as this can attract debris.
9. 9

   Install the new wheel speed sensor
   Carefully insert the new sensor straight into the knuckle bore until it seats fully against the mounting surface. The sensor should slide in smoothly without force. Misalignment or binding indicates debris in the bore or a damaged sensor. Ensure the sensor is fully seated before installing the mounting bolt.
10. 10

    Install the sensor mounting bolt
    Insert the sensor mounting bolt and hand-thread it into the knuckle. Tighten the bolt using a torque wrench to the manufacturer specification. Since no torque specification is provided in the database, tighten snugly by hand plus 1/8 turn, typically 7-10 ft-lbs for this type of fastener. Do not overtighten as this can crack the sensor body.
11. 11

    Route and secure the sensor wiring
    Route the sensor wiring harness following the exact path noted during removal. Ensure the harness is secured in all original clips and brackets with adequate slack to prevent tension during suspension travel. The wiring must not contact any moving parts, sharp edges, or heat sources.
12. 12

    Reconnect the electrical connector
    Align and firmly press the sensor electrical connector together until you hear or feel the lock tab engage. Gently tug on the connection to verify it is fully secured. Ensure no dirt or moisture entered the connector during the repair.
13. 13

    Reinstall wheel well components
    Reinstall any wheel well liner clips or fasteners that were removed for access. Ensure all components are properly secured and positioned as originally installed.

Reassembly

1. Reinstall the front wheel and torque lug nuts to manufacturer specification in a star pattern
2. Lower the vehicle to the ground
3. Reconnect the 12V auxiliary battery negative terminal
4. Ensure all tools and parts have been removed from the work area

Verification

• Connect the scan tool and clear any stored ABS fault codes
• Turn the ignition to ON position and verify the ABS warning light performs its normal self-test and extinguishes
• Perform a test drive at speeds above 15 mph to allow the ABS system to verify all wheel speed sensors are functioning
• Use the scan tool to monitor live data from all four wheel speed sensors during the test drive, confirming the repaired sensor is providing consistent signal and matching the opposite side sensor within 2-3 mph
• Verify no new ABS fault codes have been stored after the test drive
• Confirm ABS warning light remains off during normal operation

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