Complete replacement of both front strut assemblies on a 2025 Rivian EDV 500 electric delivery van, including removal of wheel assemblies and suspension components.

Warnings

Tools required

Parts

• Front strut assembly - left × 1 — Use OEM Rivian specification
• Front strut assembly - right × 1 — Use OEM Rivian specification
• Strut mount nuts (upper) × 6 — Single-use fasteners
• Lower strut-to-knuckle bolts × 4 — Single-use fasteners
• Sway bar end link nuts × 2 — As needed if damaged

Preparation

1. Disable the high-voltage system following Rivian's service procedure (typically through vehicle settings or by disconnecting the service disconnect)
2. Park vehicle on level surface and set parking brake
3. Chock rear wheels securely
4. Loosen front wheel lug nuts while vehicle is on the ground (do not remove)
5. Raise vehicle on lift or jack stands to full suspension droop position
6. Remove both front wheels completely
7. Photograph strut orientation, brake line routing, and ABS sensor positions for reference during reassembly
8. Apply penetrating lubricant to all suspension fasteners and allow to soak for 15+ minutes
9. Verify new strut assemblies match OEM specifications and are correct for left/right sides

Procedure

1. 1

   Access upper strut mounts in engine bay
   Open the hood and locate the upper strut mount towers on both sides of the front suspension area. Remove any plastic covers, trim panels, or cowl covers obstructing access to the three upper strut mount nuts. On the EDV 500, these may be behind plastic service panels. Clean the area around the upper mount nuts to prevent debris from falling into the mount area.
2. 2

   Support the lower control arm
   Position a jack stand or transmission jack under the lower control arm near the ball joint area on the side being serviced first. Raise jack until it just contacts the control arm with minimal load. This will support the suspension weight once the strut is disconnected and prevent the control arm from dropping excessively. Do not apply significant upward force.
3. 3

   Disconnect brake line and ABS sensor
   Locate and remove any brake line brackets or clips attached to the strut body. Carefully disconnect the ABS wheel speed sensor wire from any mounting points on the strut. Do not allow brake lines to hang unsupported or become kinked. Use wire or zip ties to secure brake lines and ABS wiring out of the work area. Note routing for reinstallation.
4. 4

   Disconnect sway bar end link
   Locate the sway bar end link connection at the strut. Use a wrench to hold the end link stud while loosening the retaining nut with another wrench. If the stud spins, use a Torx or hex bit to hold it from the top. Remove the nut completely and disconnect the end link from the strut. Inspect end link condition and replace if worn or damaged.
5. 5

   Remove lower strut-to-knuckle bolts
   Locate the two large bolts securing the bottom of the strut to the steering knuckle. These are typically through-bolts with nuts on the back side. Use a wrench to hold the nut while loosening the bolt with a socket and breaker bar. These fasteners will be very tight. Mark the position of any eccentric washers or alignment adjustment hardware before removal. Remove both bolts completely and separate the strut from the knuckle by pulling the knuckle outward slightly.
6. 6

   Remove upper strut mount nuts
   Working from the engine bay, use a socket to remove the three nuts securing the upper strut mount to the strut tower. Support the strut from below while removing the final nut to prevent it from falling. Once all three nuts are removed, carefully guide the strut assembly down and out from the wheel well. The strut may be heavy and awkward to maneuver.
   ⚠The strut assembly is heavy and under spring tension. Control the strut carefully as it is removed to avoid injury or damage to vehicle components.
7. 7

   Transfer components if necessary (complete assembly replacement)
   If you purchased complete strut assemblies with mounts and springs pre-installed, skip to step 9. If you purchased strut cartridges only, you must transfer the spring, upper mount, and other components from the old strut using a spring compressor. Install spring compressor tools according to manufacturer instructions, ensuring even compression on opposite sides. Compress spring until tension is removed from upper mount. Remove upper mount nut while holding the strut shaft. Remove upper mount, bearing plate, spring seat, bump stop, and spring. Inspect all components for wear.
   ⚠️Spring compressor must be properly engaged and evenly compressed. Uneven compression or tool slippage can cause violent spring release resulting in severe injury or death.
8. 8

   Assemble new strut (if not pre-assembled)
   Install bump stop and dust boot onto new strut shaft. Place spring with compressor tools still attached onto new strut, ensuring spring end seats properly in lower spring seat. Install upper spring seat, bearing plate, and upper mount in correct orientation (refer to photos from disassembly). Thread upper mount nut onto strut shaft and tighten while holding shaft from spinning. Without torque specification, tighten firmly to manufacturer recommendation. Carefully and evenly release spring compressor tension, ensuring components align properly. Remove spring compressor tools once spring is fully seated.
9. 9

   Install first new strut assembly into vehicle
   Guide the new strut assembly up into the wheel well and align the upper mount studs with the holes in the strut tower. Start all three upper mount nuts by hand to hold the strut in position. Do not fully tighten yet. Maneuver the lower strut into position and align it with the steering knuckle mounting holes.
10. 10

    Reconnect strut to steering knuckle
    Align the strut bracket with the steering knuckle mounting holes. If eccentric washers or alignment adjustments were present, reinstall them in the same orientation as marked during removal. Insert the lower strut-to-knuckle bolts and start the nuts. Position the knuckle as needed to align holes. Tighten bolts snugly but do not final torque until vehicle is at ride height. Ensure proper alignment of any factory markings.
11. 11

    Reconnect sway bar and brake components
    Reconnect the sway bar end link to the strut mounting point. Install a new nut if specified as single-use. Tighten to manufacturer specification (not available in database - use service manual). Reinstall brake line brackets and clips to the strut body in the same positions as photographed. Reconnect ABS wheel speed sensor wire and secure with any clips or ties. Ensure no wires or lines are stretched, kinked, or at risk of contact with moving parts.
12. 12

    Final tighten upper mount nuts
    Working in the engine bay, tighten all three upper strut mount nuts to manufacturer specification using a torque wrench. Without specifications in the database, consult Rivian service documentation. Typical values for similar vehicles range from 35-50 ft-lbs, but do not assume - verify for this specific vehicle. Tighten in a star pattern to ensure even seating.
13. 13

    Repeat procedure for opposite side
    Perform steps 2 through 12 for the opposite side front strut. Ensure all components are installed in mirror fashion to the first side. Verify that left and right strut assemblies are installed on their correct sides if they are side-specific.
14. 14

    Lower vehicle to ride height and final torque
    Reinstall both front wheels and start lug nuts by hand. Lower vehicle until tires just contact the ground but lift is still supporting most of weight. Torque wheel lug nuts to Rivian specification (typically 130-150 ft-lbs for this class of vehicle, but verify). Lower vehicle completely to ground. Bounce each corner of the vehicle several times to settle suspension. Final torque all lower strut-to-knuckle bolts to specification with vehicle at normal ride height under its own weight.
15. 15

    Re-enable high-voltage system and test
    Reconnect the high-voltage system or service disconnect per Rivian procedures. Start the vehicle and verify no warning lights are present on the instrument cluster. Test drive at low speed in a safe area and verify proper suspension operation, no unusual noises, and stable handling. Check for any fluid leaks or loose components. If any abnormalities are detected, stop immediately and inspect.

Reassembly

1. Reinstall any plastic covers, trim panels, or cowl covers removed for access to upper strut mounts
2. Verify all fasteners are properly torqued to specification
3. Confirm brake lines and ABS sensor wiring are properly routed and secured
4. Remove support jack from under control arm
5. Clean work area and dispose of old strut assemblies according to local regulations

Verification

• Visually inspect all connection points for proper installation and torque
• Verify upper strut mount nuts are tight and secure with no movement
• Confirm lower strut-to-knuckle bolts are properly torqued with vehicle at ride height
• Check that brake lines and ABS sensors are properly secured with no interference
• Test drive vehicle and verify smooth suspension operation with no clunking, rattling, or pulling
• Verify vehicle tracks straight during light braking (complete alignment required for final verification)
• Schedule front end alignment immediately - strut replacement affects camber, caster, and toe settings
• Re-check all fasteners after 50-100 miles of driving

More procedures for this vehicle