This procedure covers the removal and replacement of the front upper control arm bushings on a 2025 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Front upper control arm bushing (driver side) × 1 — Use OEM specification
• Front upper control arm bushing (passenger side) × 1 — Use OEM specification
• Control arm mounting hardware kit (if worn) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal and wait 2 minutes
4. If equipped with air suspension, activate service mode via vehicle settings or diagnostic tool to disable system
5. Loosen front wheel lug nuts while vehicle is on ground
6. Raise front of vehicle using floor jack at designated front lift point
7. Support vehicle on jack stands at manufacturer-specified frame contact points
8. Remove front wheels and set aside
9. Spray all control arm fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Support lower control arm
   Position a floor jack with a wooden block under the lower control arm near the ball joint to support the suspension load. Raise jack until it just contacts the arm but does not lift the vehicle. This prevents the suspension from dropping when the upper control arm is disconnected.
2. 2

   Disconnect upper ball joint from knuckle
   Remove the castle nut or fastener securing the upper ball joint to the steering knuckle. If equipped with a cotter pin, remove it first. Use a ball joint separator tool to break the taper connection between the ball joint and knuckle. Apply steady pressure with the separator tool while tapping the knuckle boss with a hammer to shock the taper loose. Do not use excessive force that could damage the knuckle.
3. 3

   Remove brake line and sensor brackets
   Identify any brake lines, ABS sensor wiring, or other components attached to the upper control arm. Remove mounting clips or brackets securing these components to the control arm. Carefully move components aside and secure with wire or zip ties to prevent damage during bushing replacement.
4. 4

   Remove upper control arm mounting bolts
   Locate the two or three bolts securing the upper control arm to the frame or subframe. These are typically at the inboard side of the control arm. Using a breaker bar and socket, remove the mounting bolts while supporting the control arm weight. Note the orientation and position of any alignment cams, shims, or eccentric washers for reassembly. Mark their position with paint or take clear photos.
5. 5

   Remove upper control arm from vehicle
   Carefully lower and remove the upper control arm from the vehicle. Inspect the ball joint, mounting points, and arm for damage or excessive wear. Clean the arm thoroughly with a wire brush, removing all dirt, rust, and debris, especially around the bushing mounting areas.
6. 6

   Press out old bushings
   Secure the control arm in a vise or on a stable work surface. Using a control arm bushing press tool set, select the appropriate receiver cup that will allow the old bushing to pass through. Position the press tool with the driver pushing against the bushing and the receiver on the opposite side. Apply steady, even pressure to press the old bushing out of the control arm. If the bushing is bonded or extremely tight, cutting the rubber away from the metal sleeve with a utility knife may help. Repeat for all bushings requiring replacement.
7. 7

   Clean bushing bores
   Once old bushings are removed, thoroughly clean the bushing bores in the control arm using a wire brush and solvent. Remove all rubber residue, corrosion, and debris. Inspect the bores for damage, cracks, or excessive wear that would prevent proper bushing seating. The bore must be smooth and clean for proper bushing installation.
8. 8

   Install new bushings
   Apply a light coating of soapy water or bushing installation lubricant to the outer surface of the new bushings and the control arm bores (do not use oil or grease). Position the new bushing at the bore opening, ensuring correct orientation if the bushing has directional markings or voids. Using the bushing press tool with appropriate driver and receiver, press the new bushing into the control arm bore. Press until the bushing is fully seated and flush with the control arm casting or at the specified depth. Verify the bushing is seated evenly on all sides.
9. 9

   Reinstall control arm to vehicle
   Lift the control arm into position and align the mounting holes with the frame or subframe attachment points. Insert the mounting bolts along with any alignment cams, shims, or eccentric washers in their original positions as marked during removal. Thread bolts in by hand first to ensure proper alignment. Do not fully tighten at this stage.
10. 10

    Reconnect upper ball joint to knuckle
    Guide the upper ball joint stud into the steering knuckle. Install the castle nut or fastener and tighten to bring the taper seats together. Ensure the ball joint seats fully into the knuckle taper. If the vehicle is equipped with a cotter pin style fastener, align the castle nut slots with the ball joint stud hole and install a new cotter pin.
11. 11

    Reattach brackets and components
    Reinstall all brake line brackets, ABS sensor wiring clips, and any other components that were removed from the upper control arm. Ensure all wiring and lines are properly routed and secured to prevent chafing or interference with moving suspension components.
12. 12

    Torque all fasteners with suspension loaded
    Before final torquing, remove the floor jack from under the lower control arm. Lower the vehicle until the wheels just contact the ground but the vehicle weight is still primarily on the jack stands. This positions the suspension at normal ride height. Torque the upper control arm mounting bolts and the ball joint fastener to manufacturer specifications. Since specific torque values are not available in the database, consult the Rivian service manual for proper torque specifications. Typically, control arm mounting bolts are torqued to 80-120 ft-lbs and ball joint nuts to 50-75 ft-lbs, but verify exact values.
13. 13

    Reinstall wheels and lower vehicle
    Reinstall the front wheels and hand-tighten lug nuts in a star pattern. Raise the vehicle slightly off the jack stands using the floor jack, remove the jack stands, and carefully lower the vehicle to the ground. Torque the wheel lug nuts to manufacturer specification (typically 110-150 ft-lbs for this vehicle class) in a star pattern.
14. 14

    Reconnect battery and exit service mode
    Reconnect the 12V battery negative terminal. If air suspension service mode was activated, cycle the ignition on and exit service mode through the vehicle settings or diagnostic tool. Allow the air suspension to reinflate and self-level if equipped.

Reassembly

1. Ensure all fasteners are torqued to specification with suspension at ride height to prevent premature bushing failure
2. Verify all brake lines and ABS wiring are properly secured and routed away from moving suspension components
3. Double-check that alignment shims and eccentric washers were reinstalled in their original positions

Verification

• Test drive the vehicle at low speed and verify no unusual noises from the front suspension
• Check for proper steering feel and response with no binding or unusual resistance
• Inspect the installation area for any fluid leaks or loose components
• Schedule a four-wheel alignment immediately after completing this repair, as suspension geometry has been altered
• After alignment, verify tire wear patterns are normal and handling characteristics are restored

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