This procedure covers the removal and replacement of the lower ball joint on a 2025 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Lower ball joint × 1 — Use OEM specification
• Lower control arm (if ball joint is not serviceable separately) × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification
• Castle nut (if not reusable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Power down vehicle completely and remove key fob from cabin
4. Disconnect 12V battery negative terminal and wait 5 minutes for system discharge
5. Loosen wheel lug nuts while vehicle is on ground
6. Raise vehicle with floor jack at manufacturer-specified jacking point
7. Support vehicle securely on jack stands rated for vehicle weight (minimum 7,000 lbs capacity)
8. Remove wheel and tire assembly completely

Procedure

1. 1

   Remove wheel speed sensor
   Disconnect the wheel speed sensor electrical connector from the mounting bracket on the lower control arm or knuckle. Remove the sensor retaining bolt and carefully extract the sensor from its bore to prevent damage during ball joint service. Secure sensor away from work area.
2. 2

   Spray penetrating oil
   Apply penetrating oil to the ball joint castle nut, control arm fasteners, and ball joint stud taper. Allow 10-15 minutes for penetration to reduce removal difficulty.
3. 3

   Support lower control arm
   Position a floor jack under the lower control arm close to the ball joint to support the suspension load. Raise jack until it just contacts the control arm but does not lift the vehicle. This prevents the suspension from dropping suddenly when the ball joint is disconnected.
4. 4

   Remove brake caliper bracket
   Remove the brake caliper and bracket assembly from the steering knuckle. Support the caliper with wire or a bungee cord - do not let it hang by the brake hose. This provides clearance to access the ball joint and knuckle area.
5. 5

   Disconnect ball joint from knuckle
   Remove the cotter pin from the ball joint castle nut and discard. Remove the castle nut from the ball joint stud. Insert a ball joint separator or pickle fork between the lower control arm and steering knuckle, then drive it in with a hammer to break the taper fit. Alternatively, use a ball joint press-type separator tool to avoid damaging components.
   ⚠Pickle fork method may damage ball joint boot - acceptable only if ball joint is being replaced
6. 6

   Lower suspension and access ball joint mounting
   Once ball joint stud is free from knuckle, carefully lower the floor jack supporting the control arm. Push the knuckle assembly upward and outward to create working clearance. Inspect the lower control arm to identify ball joint mounting method (pressed-in, bolted, or riveted).
7. 7

   Remove lower control arm (if necessary)
   If the ball joint is pressed into the control arm, remove the control arm mounting bolts at the front and rear pivot points. Note the position and orientation of any alignment shims or cams for reinstallation. Remove the control arm from the vehicle for bench work.
8. 8

   Press out old ball joint
   Using a ball joint press kit with appropriate adapters, position the control arm in the press. Select a receiver cup that fits around the ball joint housing and a driver that contacts only the ball joint body (not the stud). Press the old ball joint out of the control arm. Clean the ball joint bore thoroughly with a wire brush and inspect for damage or distortion.
   ⚠Ensure press force is applied evenly and only to the ball joint housing to prevent control arm damage
9. 9

   Press in new ball joint
   Position the new ball joint into the control arm bore with correct orientation (stud pointing in proper direction). Use ball joint press with appropriate adapters to press the new joint into place. Press until the ball joint is fully seated and flush with the control arm housing. Verify the joint rotates smoothly without binding.
10. 10

    Reinstall lower control arm
    If removed, position the lower control arm back into the mounting points. Install any alignment shims or cams in their original positions. Thread in the front and rear control arm mounting bolts but do not fully tighten yet - leave them hand-tight to allow suspension articulation during final assembly.
11. 11

    Connect ball joint to knuckle
    Raise the lower control arm with the floor jack to align the new ball joint stud with the hole in the steering knuckle. Insert the stud through the knuckle bore. Install a new castle nut onto the ball joint stud and tighten to specification (verify torque specification in service manual - not provided in database).
12. 12

    Install new cotter pin
    Align the castle nut slots with the hole in the ball joint stud. If necessary, tighten the nut slightly (never loosen) to align the slots. Install a new cotter pin through the stud hole and bend the ends to secure. Verify the castle nut cannot rotate.
13. 13

    Reinstall brake components and sensor
    Reinstall the brake caliper bracket and caliper to the steering knuckle, torquing fasteners to specification. Reinstall the wheel speed sensor into its bore with a thin coating of dielectric grease, torque the retaining bolt, and reconnect the electrical connector.
14. 14

    Torque control arm mounting bolts
    With the vehicle still on jack stands, raise the floor jack under the control arm to simulate normal ride height (suspension at approximately neutral position). Torque the front and rear control arm mounting bolts to specification (consult service manual - not provided in database). This must be done at ride height to prevent bushing preload and premature wear.
    ⚠Control arm bushings must be torqued at ride height to prevent bushing damage
15. 15

    Reinstall wheel and lower vehicle
    Install the wheel and tire assembly. Thread on lug nuts and snug them in a star pattern but do not fully tighten. Remove jack stands and carefully lower the vehicle to the ground. With vehicle weight on the wheel, torque lug nuts to specification in a star pattern (consult service manual for specific torque value).

Reassembly

1. Reconnect the 12V battery negative terminal
2. Power on the vehicle and verify no warning lights related to wheel speed sensors or suspension systems
3. Pump brake pedal several times to verify proper brake feel before moving vehicle
4. All suspension fasteners must be torqued to manufacturer specifications - consult factory service manual for exact values not provided in database

Verification

• Test drive vehicle at low speed in a safe area and verify no unusual noises, vibrations, or steering issues
• Perform a visual inspection under the vehicle to ensure all fasteners are properly installed and torqued
• Schedule a professional four-wheel alignment as suspension geometry has been affected by this repair
• Verify wheel speed sensor is functioning by checking for ABS/traction control warning lights
• Re-torque all suspension fasteners after 50-100 miles of driving
• Inspect ball joint boot for proper seating and no tears or damage

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