Front Suspension Rebuild

Complete removal, inspection, and replacement of front suspension components including control arms, ball joints, struts, and associated hardware on the Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Front upper control arm (left) × 1 — Use OEM Rivian specification
• Front upper control arm (right) × 1 — Use OEM Rivian specification
• Front lower control arm (left) × 1 — Use OEM Rivian specification
• Front lower control arm (right) × 1 — Use OEM Rivian specification
• Front strut assembly (left) × 1 — Use OEM Rivian specification
• Front strut assembly (right) × 1 — Use OEM Rivian specification
• Sway bar end links (pair) × 2 — Use OEM Rivian specification
• Tie rod end (left outer) × 1 — Use OEM Rivian specification
• Tie rod end (right outer) × 1 — Use OEM Rivian specification
• Upper ball joint (if serviceable separately) × 2 — Use OEM Rivian specification
• Lower ball joint (if serviceable separately) × 2 — Use OEM Rivian specification
• Control arm bushing kit × 1 — Use OEM Rivian specification
• Strut mount bearing assembly × 2 — Use OEM Rivian specification
• Strut bumper and dust boot kit × 2 — Use OEM Rivian specification

Preparation

1. Connect Rivian diagnostic tool and document any existing suspension-related fault codes
2. Place vehicle in Service Mode through the center display to disable high-voltage systems and prevent unexpected movement
3. Disconnect 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
4. Raise vehicle on appropriate lift or jack stands ensuring stability on frame contact points, not battery pack
5. Remove both front wheels and store with lug nuts in safe location
6. Spray all suspension fasteners with penetrating oil and allow to soak for 15-30 minutes
7. Take reference photos of suspension geometry, sensor positions, and brake line routing from multiple angles
8. Mark the orientation of adjustable components (camber bolts, eccentric washers) with paint pen before disassembly

Procedure

1. 1

   Disconnect ride height and wheel speed sensors
   Locate the ride height sensor on each front suspension assembly, typically mounted near the lower control arm. Disconnect the electrical connector and unbolt the sensor from its mounting bracket. Similarly, disconnect the ABS wheel speed sensor from the steering knuckle and carefully route the wiring away from the work area. Secure sensors to prevent damage during disassembly.
2. 2

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and carefully hang the caliper from the chassis using mechanics wire - do not allow it to hang by the brake line. Remove the caliper bracket bolts. Slide the brake rotor off the hub. If rotor is seized, use a rubber mallet on the hat section to break it free. Set aside brake components in a clean area.
3. 3

   Disconnect outer tie rod end
   Remove the castle nut from the outer tie rod end at the steering knuckle. Note the position of the tie rod jam nut for reference during reassembly. Use a tie rod separator or pickle fork to break the taper connection between the tie rod and knuckle. Count and record the number of threads exposed on the tie rod for approximate alignment reference.
   ⚠Do not strike the steering knuckle directly with a hammer as this can damage the aluminum casting. Use proper separation tools only.
4. 4

   Disconnect sway bar end links
   Locate the sway bar end link connections at both the lower control arm and the sway bar itself. Use a hex key or wrench to hold the ball stud while removing the retaining nut. If the ball stud spins freely, use locking pliers carefully on the stud shaft. Remove both left and right end links completely.
5. 5

   Separate upper ball joint from knuckle
   Remove the upper ball joint castle nut or pinch bolt (depending on EDV configuration). If using a castle nut design, use a ball joint separator to break the taper. For pinch bolt designs, loosen the bolt completely and use a small pry bar to spread the knuckle opening slightly. Support the knuckle assembly to prevent it from dropping when separated.
   ⚠The knuckle assembly with hub and motor drive unit is heavy. Have an assistant support it or use a transmission jack.
6. 6

   Separate lower ball joint and remove knuckle assembly
   Remove the lower ball joint castle nut or through-bolts. Use appropriate ball joint separator tool to break the taper connection. Once separated, carefully lower the knuckle/hub assembly and remove it from the vehicle. If the assembly includes the drive motor, be extremely careful due to weight (50+ lbs). Set on a clean workbench or padded surface.
7. 7

   Remove strut upper mounting nuts
   Working from the engine compartment or upper strut tower access panel, locate the three upper strut mount nuts. Hold the strut shaft with a wrench or hex key to prevent rotation while removing the nuts. Note the orientation of any alignment shims or washers. Support the strut assembly from below before removing the final nut.
   ⚠️The strut assembly can drop suddenly when the last nut is removed. Ensure it is properly supported.
8. 8

   Remove strut lower mounting bolts and extract assembly
   Remove the lower strut mounting bolts that connect to the lower control arm or spindle bracket. The EDV 500 typically uses two large through-bolts. Once removed, carefully extract the strut assembly from the wheel well. If the assembly binds, check for any remaining connections or brackets.
9. 9

   Remove upper control arm
   Locate the upper control arm frame mounting bolts (typically two bolts at the chassis). Support the control arm before removing bolts as it may be heavy. Remove the mounting bolts and extract the upper control arm from the vehicle. Inspect the frame mounting points for corrosion or damage. Clean mounting surfaces thoroughly with a wire brush.
10. 10

    Remove lower control arm
    The lower control arm is typically secured with a front pivot bolt and a rear bushing bolt or eccentric cam bolt. Mark the position of any eccentric adjusters before removal. Support the control arm before removing the final bolt. Remove both mounting bolts and extract the lower control arm. Inspect the subframe mounting points for wear or damage.
11. 11

    Inspect and prepare new components
    Thoroughly inspect all removed components for wear patterns, damage, and failure modes to understand the root cause of suspension issues. Clean all mating surfaces on the chassis, knuckle, and subframe with wire brush and brake cleaner. Apply aluminum anti-seize to all threaded bolt areas and mounting surfaces. Pre-fit all new components to verify correct parts before installation. If replacing bushings only, use appropriate press tools to remove old bushings and install new ones.
12. 12

    Install new lower control arms
    Position the new lower control arm into place and start both front and rear mounting bolts by hand. Align any eccentric adjusters to the marks made during disassembly. Do not fully tighten bolts at this stage - leave them finger tight plus 1-2 turns. The control arm must be loaded at ride height before final torquing to prevent bushing bind.
13. 13

    Install new upper control arms
    Position the new upper control arm to the frame mounting points. Install mounting bolts and start threads by hand. Ensure any alignment shims or cams are positioned as originally found. Similar to lower arms, do not fully tighten at this stage. Leave bolts snug but not torqued to specification.
14. 14

    Install new strut assemblies
    If installing complete strut assemblies, position the strut into the wheel well from below, aligning the upper mount studs with the strut tower holes. Install upper mount nuts loosely. Align the lower strut mount with the lower control arm or knuckle bracket and install mounting bolts. Thread all fasteners but do not torque yet. Verify strut is properly seated in all mounting locations.
15. 15

    Reattach knuckle assembly to ball joints
    Carefully lift the knuckle/hub assembly into position. Connect the lower ball joint first, installing the castle nut or through-bolts loosely. Then connect the upper ball joint, again leaving fasteners loose. Ensure the knuckle moves freely through its range of motion before proceeding. Install new cotter pins if using castle nut designs.
16. 16

    Reconnect tie rod ends and sway bar links
    Thread the outer tie rod end into the steering knuckle, using the thread count documented during disassembly as a starting point. Install and hand-tighten the castle nut. Install new sway bar end links, connecting them to both the control arm and sway bar. Hand-tighten all fasteners. These will need final torquing and the tie rods will require alignment adjustment.
17. 17

    Reinstall brake components and wheels
    Reinstall the brake rotor onto the hub. Install the caliper bracket and torque to specification if values are available. Mount the brake caliper and torque mounting bolts. Reconnect the ABS wheel speed sensor to the knuckle and secure the wiring in original routing. Reinstall wheels and snug lug nuts in a star pattern.
18. 18

    Load suspension and torque all fasteners
    Lower the vehicle until the suspension is at normal ride height but wheels are still slightly off the ground. This loads the suspension bushings in their normal operating position. Working systematically, torque all suspension fasteners to Rivian specifications in this order: control arm frame bolts, strut mounting bolts (upper and lower), ball joint fasteners, sway bar end links, and tie rod ends. After torquing, fully lower vehicle and torque wheel lug nuts to specification in a star pattern.
    ℹ️Since torque specifications are not available in this database, you must obtain them from Rivian service documentation before performing this step. Do not guess at torque values.
19. 19

    Reconnect sensors and restore vehicle systems
    Reconnect all ride height sensors and verify secure mounting. Double-check all electrical connectors are fully seated and latched. Reconnect the 12V battery negative terminal. Exit Service Mode through the vehicle display. Use the Rivian diagnostic tool to clear any stored fault codes and perform a suspension system test if available in the software.

Reassembly

1. Verify all fasteners have been torqued to specification and no tools or parts remain in the wheel wells
2. Pump the brake pedal several times to restore proper brake feel and pad position
3. Inspect for any fluid leaks, unusual noises, or loose components before moving the vehicle
4. Test drive the vehicle in a safe area at low speeds to verify proper suspension operation and steering feel
5. Schedule a professional four-wheel alignment immediately - alignment is mandatory after suspension rebuild and cannot be skipped

Verification

• Perform a visual inspection of all installed components verifying proper seating and orientation
• Verify all electrical connectors are properly seated and ride height sensors are functioning
• Check that all fasteners are properly torqued using a calibrated torque wrench
• Test drive vehicle and verify no pulling, vibration, or unusual noises during straight-line driving and turning
• Verify proper steering wheel return to center after turns
• Using diagnostic tool, confirm no suspension-related fault codes are present
• After alignment, verify all suspension angles (camber, caster, toe) are within Rivian specifications
• Re-check all fastener torques after 50-100 miles of driving and again after 500 miles

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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