This procedure replaces the front coil springs on a 2025 Rivian EDV 500 electric delivery van, requiring suspension disassembly and use of a spring compressor.

Warnings

Tools required

Parts

• Front coil spring × 2 — Use OEM Rivian specification
• Upper strut mount bearing (if worn) × 2 — Use OEM specification
• Strut dust boot (if damaged) × 2 — Use OEM specification
• Suspension hardware kit (nuts, bolts) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle using proper lift points per Rivian service manual
5. Support vehicle on commercial-grade jack stands rated for at least 7,000 lbs
6. Remove front wheel and tire assembly
7. Spray all suspension fasteners with penetrating oil and allow to soak for 15 minutes
8. Mark alignment position of all adjustable components with paint pen before disassembly
9. Have spring compressor tool ready and inspect for damage or wear

Procedure

1. 1

   Disconnect brake line and ABS sensor
   Locate the brake line bracket attached to the strut assembly. Remove the brake line mounting bolt and carefully reposition the brake line to provide clearance. Disconnect the ABS wheel speed sensor connector and remove any clips securing the sensor wire to the strut. Do not allow brake line to hang unsupported; support with wire or bungee cord.
2. 2

   Remove stabilizer bar end link
   Locate the stabilizer bar end link connection to the strut assembly. Use a wrench to hold the end link stud while removing the retaining nut with another wrench. Separate the end link from the strut. If the ball joint spins, use locking pliers on the stud or use a ball joint separator.
3. 3

   Disconnect lower control arm ball joint
   Remove the cotter pin (if equipped) and castle nut securing the lower ball joint to the steering knuckle. Use a ball joint separator or pickle fork to carefully separate the ball joint taper from the knuckle. Do not damage the ball joint boot. Support the lower control arm so it does not drop suddenly when separated.
   ⚠The control arm will drop under spring tension when the ball joint is separated. Ensure the spring compressor is installed before this step or support the control arm with a jack.
4. 4

   Remove upper strut mount nuts
   Open the hood and locate the upper strut mount tower inside the engine compartment. Remove the protective cap covering the strut mount. Have an assistant support the strut assembly from below, or use a transmission jack. Remove the three upper strut mount nuts. Do not remove the center strut shaft nut at this time. Lower the strut assembly carefully once all upper nuts are removed.
5. 5

   Remove strut assembly from vehicle
   With the upper mount released and lower connections disconnected, carefully maneuver the complete strut assembly out of the wheel well. The assembly is heavy and awkward; use both hands and proper lifting technique. Place the strut assembly on a clean, stable workbench.
6. 6

   Install spring compressor
   Position the coil spring compressor tool onto the coil spring, ensuring the compressor hooks are fully engaged in the coil grooves on opposite sides (180 degrees apart). Install at least 3-4 full coils from the end for maximum safety. Verify the compressor is seated properly and cannot slip. Begin tightening the compressor evenly, alternating sides to maintain balanced compression.
   ⚠️This is the most dangerous step. Verify the spring compressor is fully engaged and cannot slip. Compress slowly and check engagement frequently. Stand to the side, never in line with the spring ends.
7. 7

   Compress spring and remove strut shaft nut
   Continue compressing the spring evenly until all tension is released from the upper strut mount (you should be able to wiggle the mount slightly). Use a wrench to hold the strut shaft while removing the upper strut shaft nut. The shaft may have a hex feature for this purpose. Remove the nut completely but keep all components in order for reassembly.
8. 8

   Disassemble strut components
   Carefully remove the upper strut mount, bearing plate, and upper spring seat from the strut shaft. Inspect the bearing for smooth rotation and the mount for cracks or deterioration. Slowly and carefully release tension from the spring compressor. Once fully relaxed, remove the old coil spring from the compressor. Inspect the strut dust boot and bump stop for damage.
9. 9

   Install new coil spring
   Place the new coil spring into the spring compressor, ensuring the spring end is positioned in the same orientation as the original (note the shaped end that seats into the lower spring seat). Compress the new spring evenly until it is compressed to approximately the same length as the original spring was when removed from the strut.
   ⚠Verify the new spring is the correct part number for the EDV 500. Front springs may differ based on GVWR rating and vehicle configuration.
10. 10

    Reassemble strut components
    Slide the compressed new spring onto the strut shaft, aligning the lower spring end with the seat on the strut body. Install the bump stop and dust boot onto the strut shaft. Install the upper spring seat, ensuring the spring end is properly seated in the upper seat recess. Install the bearing plate (if equipped) with the bearing correctly oriented. Install the upper strut mount.
11. 11

    Install and torque strut shaft nut
    Thread the strut shaft nut onto the shaft by hand. Hold the strut shaft with a wrench and tighten the shaft nut. Without factory torque specifications, tighten to secure the assembly firmly while avoiding over-torquing the bearing. Once assembled, slowly and evenly release the spring compressor tension. Verify all components seat properly as tension is released. Remove the spring compressor.
    ⚠You must obtain the factory torque specification for the strut shaft nut before completing this step. Typical values are 50-70 ft-lb but vary by manufacturer.
12. 12

    Install strut assembly into vehicle
    Lift the complete strut assembly into position in the wheel well. Align the upper strut mount studs with the holes in the strut tower. Thread the three upper mount nuts onto the studs and tighten by hand. Align the lower strut connection points with the steering knuckle and control arm.
13. 13

    Secure upper strut mount
    Torque the three upper strut mount nuts in a star pattern. Without factory specifications, tighten firmly to secure the mount to the tower. Install the protective cap over the strut mount. These fasteners are critical to vehicle safety and must be properly torqued per OEM specifications.
14. 14

    Reconnect lower ball joint and stabilizer link
    Raise the lower control arm into position and insert the ball joint taper into the steering knuckle. Install the castle nut and torque appropriately. Install a new cotter pin if equipped. Reconnect the stabilizer bar end link to the strut and install the retaining nut. Hold the stud while torquing the nut.
15. 15

    Reconnect brake line and sensors
    Reattach the brake line bracket to the strut with the mounting bolt. Reconnect the ABS wheel speed sensor connector and secure the sensor wire with all clips. Verify the brake line has adequate clearance through full suspension travel and steering range. Check that no wires or hoses are pinched or stretched.

Reassembly

1. Install wheel and tire assembly, threading lug nuts by hand first
2. Lower vehicle until tire just contacts ground to prevent wheel rotation
3. Torque wheel lug nuts to specification in a star pattern
4. Fully lower vehicle and remove jack stands
5. Repeat entire procedure for opposite side if replacing both springs
6. Bounce front end several times to settle suspension components
7. Double-check that all fasteners have been installed and properly torqued

Verification

• Start vehicle and verify no warning lights related to ABS or traction control
• Test drive in a safe area at low speed, listening for any unusual noises or clunking
• Verify steering feels normal with no pulling or unusual feedback
• Check for proper ride height - vehicle should sit level side-to-side
• Schedule a professional four-wheel alignment immediately after this repair
• Inspect all suspension components after 50-100 miles of driving for proper seating and no looseness
• Re-torque all suspension fasteners after first 100 miles if possible

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