This procedure covers the removal and replacement of upper and lower ball joints on the 2025 Rivian EDV 500 electric delivery van's front suspension.

Warnings

Tools required

Parts

• Upper ball joint (per side) × 2 — Use OEM specification
• Lower ball joint (per side) × 2 — Use OEM specification
• Ball joint castle nut (upper) × 2 — Use OEM specification
• Ball joint castle nut (lower) × 2 — Use OEM specification
• Cotter pins × 4 — Use OEM specification
• Control arm bushing kit (if worn) × 1 — Inspect during service

Preparation

1. Park vehicle on level surface and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes for system shutdown
4. Loosen front wheel lug nuts while vehicle is on ground
5. Lift front of vehicle using manufacturer-specified lift points and secure on jack stands
6. Remove front wheels and store safely
7. Spray all ball joint nuts and fasteners with penetrating oil and allow to soak 15-20 minutes
8. Take photos of suspension geometry and orientation for reference during reassembly

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the lower control arm near the ball joint area. Raise jack until it just contacts the control arm with light pressure. This supports the suspension load and prevents sudden movement when fasteners are removed.
2. 2

   Disconnect wheel speed sensor
   Locate the ABS wheel speed sensor connector at the upper control arm or knuckle area. Disconnect the electrical connector and carefully unclip the sensor wire from any brackets along the control arm to prevent damage during ball joint removal.
3. 3

   Remove upper ball joint castle nut
   Remove the cotter pin from the upper ball joint castle nut using pliers or wire cutters. Using a socket and breaker bar, remove the castle nut from the upper ball joint stud. Keep the nut for reference when installing the new component.
4. 4

   Separate upper ball joint from knuckle
   Using a ball joint separator or pickle fork, carefully separate the upper ball joint stud from the steering knuckle. Position the tool to avoid damaging the CV boot or brake components. Strike the tool firmly with a hammer until the taper releases. The knuckle will drop slightly when separated.
5. 5

   Remove lower ball joint castle nut
   Remove the cotter pin from the lower ball joint castle nut. While supporting the lower control arm with the jack, remove the castle nut from the lower ball joint stud. Do not allow the control arm to drop suddenly after nut removal.
6. 6

   Separate lower ball joint from knuckle
   Use the ball joint separator to disconnect the lower ball joint stud from the steering knuckle. Apply force carefully as the lower joint bears more load. Once separated, carefully lower the jack supporting the control arm and pivot the knuckle assembly out of the way to access the ball joint mounting points.
7. 7

   Remove upper ball joint from control arm
   The upper ball joint is typically pressed or bolted into the upper control arm. If bolted, remove the mounting bolts from the top of the control arm. If pressed, use a ball joint press kit with the appropriate adapters to press the old ball joint out of the control arm bore. Clean the control arm bore thoroughly with a wire brush.
8. 8

   Remove lower ball joint from control arm
   Access the lower ball joint mounting hardware, which may require removing additional fasteners securing the ball joint to the lower control arm. Use the ball joint press kit to press out the lower ball joint if it is a press-fit design. Inspect the control arm bore for damage or excessive wear before installation.
9. 9

   Install new lower ball joint
   Using the ball joint press kit with proper adapters, press the new lower ball joint into the control arm bore. Ensure the joint is fully seated and oriented correctly with any mounting holes aligned. If bolt-in type, install new bolts and tighten to manufacturer specifications. Note: Torque specifications not available in database - consult service manual.
10. 10

    Install new upper ball joint
    Press or bolt the new upper ball joint into the upper control arm. Ensure proper seating and orientation. The dust boot should face downward and the stud should move freely through its range of motion. Verify no binding or unusual resistance.
11. 11

    Reconnect steering knuckle to ball joints
    Raise the steering knuckle into position. Use the floor jack to raise the lower control arm and align the lower ball joint stud with the knuckle bore. Insert the lower ball joint stud into the knuckle, then install the new castle nut hand-tight. Align the upper ball joint stud with the upper knuckle bore and install the upper castle nut hand-tight.
12. 12

    Torque ball joint castle nuts
    Torque the lower ball joint castle nut to manufacturer specification, then continue tightening to the next castle slot that aligns with the cotter pin hole. Install a new cotter pin and bend the ends securely. Repeat for the upper ball joint castle nut. Note: Torque specifications not available in database - consult Rivian service manual for exact values.
13. 13

    Reconnect wheel speed sensor and inspect
    Reconnect the ABS wheel speed sensor electrical connector and secure the wiring to all original clip locations. Ensure wiring has adequate slack and will not contact moving suspension components or the tire during full suspension travel and steering movement.
14. 14

    Verify suspension movement and clearances
    With the jack still supporting the control arm, cycle the suspension through its travel range and turn the steering full lock to both directions. Verify no interference, binding, or unusual noises. Check that all fasteners are tight and new cotter pins are properly installed.

Reassembly

1. Remove the floor jack from under the control arm
2. Repeat the entire procedure for the opposite side if replacing both sides
3. Reinstall front wheels and hand-tighten lug nuts
4. Lower vehicle to the ground and torque lug nuts to specification in a star pattern
5. Reconnect 12V auxiliary battery negative terminal
6. Start vehicle and verify no warning lights related to ABS or suspension systems

Verification

• Test drive vehicle at low speed in a safe area and verify no clunking, popping, or abnormal noises from front suspension
• Verify steering returns to center properly and there is no pulling to either side
• Check for proper ABS operation by verifying no warning lights on instrument cluster
• Schedule and complete four-wheel alignment immediately - alignment is mandatory after ball joint replacement
• After alignment, re-torque all ball joint castle nuts and verify cotter pins are secure
• After 50-100 miles, re-inspect all ball joint fasteners and cotter pins for security

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