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

Warnings

Tools required

Parts

• Rear control arm bushing kit (inner) × 2 — Use OEM specification
• Rear control arm bushing kit (outer) × 2 — Use OEM specification
• Control arm mounting hardware kit (if corroded) × 1 — Use OEM specification

Preparation

1. Place vehicle in service mode per manufacturer instructions to disable high-voltage systems
2. Park vehicle on level surface and engage parking brake
3. Place wheel chocks at front wheels
4. Raise vehicle on lift or jack stands ensuring proper weight capacity for EV
5. Remove rear wheels and set aside
6. Spray all control arm fasteners with penetrating oil and allow to soak for 10-15 minutes
7. Visually inspect rear suspension for additional damage or worn components
8. Take reference photos of suspension geometry and fastener positions
9. Mark control arm orientation relative to mounting points with paint pen

Procedure

1. 1

   Support rear suspension
   Position hydraulic floor jack under the rear axle or lower control arm mounting point on the side being serviced. Raise jack until it just contacts and slightly supports the suspension weight, but does not lift the vehicle. This prevents suspension droop when fasteners are removed.
2. 2

   Disconnect rear brake caliper (if necessary)
   If the control arm removal requires additional clearance, remove the brake caliper mounting bolts and secure the caliper to the frame with mechanics wire. Do not allow caliper to hang by the brake hose. On EDV models, the caliper may not need removal depending on which control arm is being serviced.
3. 3

   Remove wheel speed sensor connector
   Disconnect the rear wheel speed sensor electrical connector if routed near the control arm. Carefully unclip any wiring harness retainers attached to the control arm to prevent damage during removal.
4. 4

   Document fastener torque
   Before removing fasteners, use your torque wrench to check and document the breakaway torque of the rear control arm mounting bolts/nuts at both the frame side and knuckle side. Record these values for reference during reinstallation since factory specifications are not available in the database.
5. 5

   Remove outer control arm mounting bolt
   Remove the bolt securing the control arm to the rear knuckle or hub assembly. This is typically the outer mounting point. Support the control arm as the fastener is removed to prevent it from falling. Keep all fasteners organized and note their original positions.
6. 6

   Remove inner control arm mounting bolt
   Remove the bolt(s) securing the control arm to the frame or subframe mounting bracket. This is the inner pivot point where the bushing(s) will be replaced. Carefully lower the control arm and remove it from the vehicle. Note the orientation and any alignment shims or washers present.
7. 7

   Inspect control arm
   Clean the control arm thoroughly with a wire brush. Inspect for cracks, bends, or other damage. Check the bushing bores for corrosion, scoring, or out-of-round conditions. If control arm is damaged, replacement is required rather than bushing service.
8. 8

   Remove old bushings
   Using a hydraulic press and appropriate bushing removal tools or a control arm bushing press kit, carefully press out the old bushings from the control arm. Apply pressure evenly and slowly to avoid damaging the control arm housing. The outer sleeve of the bushing may need to be cut or collapsed inward if seized.
9. 9

   Prepare control arm for new bushings
   Clean the bushing bores thoroughly with a wire brush and solvent to remove all rust, old rubber, and debris. Inspect bores for damage. Apply a thin coat of the bushing manufacturer's recommended lubricant (typically soapy water or specific installation lube, NOT grease) to the bushing bore.
10. 10

    Install new bushings
    Position the new bushing at the bore opening, ensuring correct orientation (note any directional markings or voids in the bushing design). Using the hydraulic press and installation tools, press the new bushing into the control arm bore slowly and evenly. Press until the bushing is fully seated and flush with the control arm housing or at the manufacturer's specified depth.
11. 11

    Verify bushing installation
    Confirm both bushings (if applicable) are fully seated, properly aligned, and the inner sleeve rotates freely within the outer bushing. Check that no rubber material is pinched or damaged. Measure bushing protrusion if specifications are available.
12. 12

    Reinstall control arm to frame
    Position the control arm back into the frame/subframe mounting location. Install the inner mounting bolt(s) with any original shims or washers in their exact original positions. Thread the fastener by hand first to ensure proper alignment. Do not fully tighten at this stage.
13. 13

    Reinstall control arm to knuckle
    Align the outer end of the control arm with the knuckle mounting point. You may need to use the hydraulic jack to adjust suspension height for proper alignment. Install the outer mounting bolt and thread by hand. Do not fully tighten yet.
14. 14

    Torque control arm fasteners
    With the vehicle weight supported on the suspension (lower vehicle onto jack stands or adjust floor jack so suspension is at normal ride height), torque all control arm fasteners. Since manufacturer torque specifications are not available, apply torque matching the documented values from step 4, or use industry standard torque values for the specific fastener grade and size (typically 90-120 ft-lbs for grade 10.9 M14 bolts common in this application). Apply thread locker to fasteners per manufacturer recommendations.

Reassembly

1. Reconnect wheel speed sensor connector and secure all wiring harness clips
2. Reinstall brake caliper if removed and torque mounting bolts appropriately
3. Reinstall rear wheels and torque lug nuts to manufacturer specification (typically 140-150 ft-lbs for commercial EVs)
4. Repeat entire procedure for opposite side if both sides are being serviced
5. Lower vehicle to ground
6. Exit service mode and restore vehicle to normal operation

Verification

• Test drive vehicle at low speed in a safe area and verify no unusual noises, vibrations, or handling issues from the rear suspension
• Re-torque all control arm fasteners after 50-100 miles of driving
• Schedule four-wheel alignment immediately - verify rear toe, camber, and thrust angle are within specification
• Visually inspect installation after alignment for proper bushing seating and fastener tightness
• Monitor for any abnormal tire wear patterns over the next 500-1000 miles

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