Air Suspension Height Sensor

This procedure covers the removal and replacement of an air suspension height sensor on a 2025 Rivian EDV 500 delivery van equipped with dual motor AWD and adaptive air suspension.

Warnings

Tools required

Parts

• Air suspension height sensor × 1 — Use OEM Rivian specification
• Sensor mounting hardware kit (if corroded) × 1 — Use OEM specification
• Connector weather seal boot (if damaged) × 1 — Use OEM specification

Preparation

1. Connect diagnostic tool and retrieve stored fault codes to identify which corner's height sensor requires replacement (LF, RF, LR, or RR)
2. Park vehicle on level surface and engage parking brake
3. Use diagnostic tool to enter air suspension service mode, which will vent system and maintain ride height
4. Disconnect 12V battery negative terminal located in front cargo area behind service panel
5. Wait 5 minutes for vehicle systems to fully power down
6. Raise and safely support vehicle on lift or jack stands at designated lift points
7. Remove wheel at corner with faulty height sensor using 21mm socket

Procedure

1. 1

   Access height sensor mounting location
   Remove the inner fender liner or wheel well access panel to expose the height sensor. For front sensors, remove plastic push clips and T25 Torx fasteners securing the liner forward section. For rear sensors, remove the cargo area trim panel on the interior side to access the sensor from inside the van body. The height sensor is mounted on the suspension control arm or axle housing with a link rod connecting to the chassis.
2. 2

   Disconnect height sensor electrical connector
   Locate the sensor electrical connector approximately 8-12 inches from the sensor body along the wiring harness. Press the connector locking tab and carefully pull the connector apart. Inspect the connector pins for corrosion or damage. If corrosion is present, clean with contact cleaner and wire brush before proceeding.
3. 3

   Document sensor link arm position
   Before removing the sensor, note the position and angle of the link arm connected between the sensor and chassis mounting point. Take a photo with your phone for reference during installation. The link arm position is critical for proper sensor calibration and ride height accuracy.
4. 4

   Disconnect sensor link arm from chassis
   Locate the ball joint or clip connection at the chassis end of the sensor link arm. Using a 10mm socket, remove the retaining bolt or press the clip release to disconnect the link arm from the chassis bracket. Support the link arm to prevent it from swinging and damaging the sensor body.
5. 5

   Remove height sensor mounting fasteners
   Using a T30 Torx driver, remove the two or three fasteners securing the height sensor body to its mounting bracket on the suspension component. The sensor is typically mounted to the lower control arm, trailing arm, or axle housing depending on the corner being serviced. Support the sensor as you remove the final fastener.
6. 6

   Remove height sensor assembly
   Carefully extract the height sensor with its attached link arm from the mounting location. Guide the wiring harness through any clips or routing channels. Inspect the mounting bracket and link arm ball joints for wear, damage, or excessive play that could affect new sensor operation.
7. 7

   Compare old and new sensors
   Place the old and new height sensors side by side and verify they are identical in mounting hole pattern, link arm length, and connector type. If the new sensor came without a link arm pre-installed, transfer the link arm from the old sensor, ensuring the ball joint is in good condition and not worn.
8. 8

   Install new height sensor to mounting bracket
   Position the new height sensor on the suspension mounting bracket, aligning the mounting holes. Install the T30 Torx fasteners finger-tight initially to allow minor adjustment. Ensure the sensor body is oriented correctly with the link arm connection point positioned toward the chassis mounting location.
9. 9

   Connect sensor link arm to chassis
   Align the sensor link arm with the chassis mounting bracket, matching the position documented in step 3. Install the retaining bolt or clip to secure the link arm to the chassis bracket. If using a bolt, install the 10mm fastener finger-tight at this stage. The link arm should move freely through its range of motion without binding.
10. 10

    Tighten all sensor mounting hardware
    Tighten the sensor body mounting fasteners in a cross pattern to ensure even seating. Since no torque specifications are available in the database, tighten the T30 Torx fasteners firmly by hand plus approximately 1/4 turn. Tighten the 10mm link arm chassis bolt similarly. Do not overtighten as the mounting points may be into aluminum or composite materials.
11. 11

    Route and secure wiring harness
    Route the sensor wiring harness through the original clips and channels, ensuring it does not contact any moving suspension components, sharp edges, or heat sources. Leave appropriate slack for full suspension travel. Secure with existing clips or new zip ties if necessary, maintaining factory routing path.
12. 12

    Reconnect sensor electrical connector
    Clean both halves of the electrical connector with contact cleaner if not already done. Apply a small amount of dielectric grease to the connector pins to prevent corrosion. Press the connector halves together firmly until the locking tab clicks into place. Gently tug on the connector to verify it is fully seated.
13. 13

    Reinstall wheel well components
    Reinstall the inner fender liner or interior trim panel removed in step 1. Ensure all clips and fasteners are properly seated. Verify no wiring harnesses or components are pinched behind the panels.
14. 14

    Reinstall wheel and lower vehicle
    Reinstall the wheel and torque lug nuts to Rivian specification (typically 140 lb-ft, but verify with factory documentation). Lower the vehicle to the ground and remove jack stands or lower lift completely. Reconnect the 12V battery negative terminal.
15. 15

    Calibrate height sensor and verify operation
    With the vehicle on level ground and diagnostic tool connected, exit air suspension service mode to allow the system to pressurize. Perform height sensor calibration procedure using the diagnostic tool, which typically involves commanding the suspension through its full range of travel at each corner. Clear all fault codes and verify the new height sensor is reporting valid ride height data. Test drive the vehicle and verify suspension operates normally with no warning lights.

Reassembly

1. All components should be reassembled in reverse order of removal
2. Ensure wiring harness routing matches factory configuration with adequate slack for suspension travel
3. Verify all electrical connectors are fully seated with locking tabs engaged
4. Confirm wheel lug nuts are torqued to specification

Verification

• Connect diagnostic tool and verify new height sensor is reporting valid ride height values that change appropriately when suspension is compressed or extended
• Clear all fault codes and verify no new codes are present after calibration
• Test air suspension in all available ride height modes (normal, low, high) and confirm vehicle achieves target heights within specification
• Perform test drive including various road conditions and verify suspension operates smoothly without faults
• Check that suspension returns to normal ride height after shutting down vehicle and restarting
• Inspect sensor mounting area after test drive to ensure no fasteners have loosened and wiring remains properly routed

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