This procedure covers the removal and replacement of the upper ball joint on a 2025 Rivian EDV 500 commercial van with dual motor AWD drivetrain.

Warnings

Tools required

Parts

• Upper ball joint assembly × 1 — Use OEM specification
• Upper control arm bolts (if replacement required) × 2 — Use OEM specification
• Cotter pin or retaining clip × 1 — Use OEM specification
• Wheel hub nut (recommend replacement) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal and wait 10 minutes for system power-down
4. Verify high voltage system is inactive using vehicle interface (screen should be completely off)
5. Loosen wheel lug nuts while vehicle is on ground (do not remove)
6. Raise front of vehicle using floor jack at designated front lift point
7. Support vehicle on heavy-duty jack stands placed at reinforced frame rails, avoiding battery enclosure and electrical components
8. Remove wheel and tire assembly completely
9. Spray penetrating oil on upper ball joint castle nut, control arm bolts, and steering knuckle interface
10. Allow penetrating oil to soak for at least 15 minutes

Procedure

1. 1

   Remove wheel speed sensor and brake line brackets
   Disconnect the wheel speed sensor connector from the harness. Remove any brake line or ABS sensor brackets attached to the upper control arm or steering knuckle that may interfere with ball joint access. Secure brake line and sensor wiring away from work area using wire or zip ties to prevent damage.
2. 2

   Support the lower control arm
   Position a floor jack under the lower control arm, close to the ball joint area. Raise jack just enough to slightly compress the suspension and support the weight of the knuckle assembly. This prevents the suspension from dropping suddenly when the upper ball joint is disconnected and maintains alignment positioning.
3. 3

   Remove upper ball joint castle nut
   Remove the cotter pin or retaining clip from the upper ball joint castle nut. Using a socket and breaker bar, loosen and remove the castle nut from the ball joint stud. Note the orientation and number of threads exposed before removal for reference during reassembly. Keep the castle nut if in good condition.
4. 4

   Separate ball joint from steering knuckle
   Use a pickle fork or approved ball joint separator tool to break the taper fit between the ball joint stud and steering knuckle. Insert the tool between the control arm and knuckle, then strike firmly with a hammer or apply separator tool pressure. Alternatively, use a ball joint puller if available. The joint will separate with a distinct pop. Do not damage the knuckle taper bore.
5. 5

   Access upper control arm ball joint mounting
   With the ball joint stud freed from the knuckle, pivot the knuckle assembly downward (supported by the jack under lower control arm). This exposes the ball joint mounting area on the upper control arm. If the ball joint is riveted, mark rivet locations with a marker. If bolted, identify bolt heads and access points on the control arm.
6. 6

   Remove ball joint from upper control arm
   If ball joint is pressed into the control arm: Use a ball joint press set with appropriate adapters. Position the press to drive the ball joint downward out of the control arm bore. Apply steady pressure until the joint is fully removed. If riveted: Drill out rivets using progressively larger drill bits (start 1/8 inch, finish with rivet diameter size). Use a chisel to remove rivet heads if necessary. If bolted: Remove mounting bolts using appropriate sockets.
7. 7

   Clean control arm ball joint bore
   Thoroughly clean the ball joint mounting bore in the upper control arm using a wire brush and clean shop towels. Remove all rust, debris, old grease, and metal shavings. Inspect the bore for damage, cracks, or elongation. The bore must be smooth and round for proper press fit. If damaged, the entire control arm requires replacement.
8. 8

   Install new ball joint into control arm
   Position the new ball joint at the control arm bore opening, ensuring proper orientation (stud pointing downward). If ball joint has a specific rotational orientation, align according to manufacturer markings. Using the ball joint press with receiving cup adapter, press the new joint into the bore until fully seated and flush with the control arm surface. The joint should require significant force to install and be tight in the bore.
9. 9

   Secure ball joint to control arm
   If the new ball joint came with bolts: Install bolts through control arm and ball joint, then tighten to manufacturer specification (spec required before final torque). If original was riveted and new joint includes bolts, install per kit instructions. Ensure all fasteners are properly threaded and seated before torquing.
10. 10

    Reconnect ball joint to steering knuckle
    Clean the taper bore in the steering knuckle using a wire brush. Raise the knuckle assembly using the floor jack under the lower control arm. Align the ball joint stud with the knuckle taper bore and guide the stud through the opening. The taper should begin to seat as you raise the knuckle into position.
11. 11

    Install and torque castle nut
    Thread the castle nut onto the ball joint stud by hand until snug. Using a torque wrench, tighten the castle nut to the manufacturer-specified torque value (REQUIRED - must obtain from Rivian service data before completing this step). Align the castle nut slots with the ball joint stud hole and install a new cotter pin or retaining clip. Bend cotter pin ends to secure.
12. 12

    Reinstall sensor and brake hardware
    Reconnect the wheel speed sensor connector to the harness, ensuring the connector locks fully. Reinstall any brake line brackets or ABS sensor brackets removed earlier. Verify all wiring and brake lines are properly routed, secured, and have adequate clearance from suspension travel and rotating components.
13. 13

    Reinstall wheel and lower vehicle
    Mount the wheel and tire assembly onto the hub. Install lug nuts and tighten in a star pattern by hand. Lower the vehicle carefully from jack stands using the floor jack. Once the tire contacts the ground with partial vehicle weight, torque the lug nuts to manufacturer specification in a star pattern (obtain specification from Rivian service data). Fully lower the vehicle and remove jack and jack stands.

Reassembly

1. Reconnect the 12V battery negative terminal and ensure proper connection
2. Power on the vehicle and verify all dashboard warning lights behave normally
3. Check for any suspension warning messages or ABS system faults
4. Verify wheel speed sensor is functioning (no ABS warning light)
5. Apply and release parking brake several times to verify proper operation

Verification

• Test drive the vehicle in a safe area at low speeds, listening for any clunking, popping, or unusual noises from the front suspension
• Perform gentle steering inputs at low speed to verify smooth operation without binding
• Brake firmly from moderate speed to confirm ABS operation and wheel speed sensor function
• Perform a complete wheel alignment at a qualified facility with EV experience - alignment is MANDATORY after upper ball joint replacement
• After 50-100 miles, re-verify castle nut torque and cotter pin security
• Check for any play in the upper ball joint by grasping the tire at 12 and 6 o'clock positions and attempting to rock it - there should be no perceptible movement
• Inspect the area around the ball joint for any signs of grease leakage or looseness

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