This procedure covers the removal and replacement of the front knuckle/spindle assembly on a 2025 Rivian EDV 500 electric delivery van with dual motor AWD.

Warnings

Tools required

Parts

• Front knuckle/spindle assembly × 1 — Use OEM specification
• Axle nut × 1 — Use OEM specification
• Lower ball joint nut × 1 — Use OEM specification
• Upper ball joint nut × 1 — Use OEM specification
• Tie rod end nut × 1 — Use OEM specification
• ABS sensor O-ring × 1 — Use OEM specification
• Brake caliper bracket bolts × 2 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Power down vehicle completely using touchscreen shutdown procedure
3. Disconnect 12V auxiliary battery negative terminal
4. Loosen front wheel lug nuts while vehicle is on ground
5. Raise vehicle on lift or jack stands at manufacturer-specified lift points
6. Remove front wheel and tire assembly
7. Spray all fasteners to be removed with penetrating oil and allow to soak for 10 minutes
8. Place drain pan under brake caliper area in case of fluid spillage

Procedure

1. 1

   Remove axle nut
   Have an assistant apply brakes or use a pry bar wedged against wheel studs to prevent hub rotation. Use breaker bar to loosen and remove the front axle nut. This nut is typically torqued to very high specification and may require significant force to break loose.
2. 2

   Remove brake caliper and bracket
   Remove the two brake caliper mounting bolts and carefully lift the caliper off the rotor. Support the caliper with wire or a bungee cord to avoid placing tension on the brake hose. Do not let caliper hang by the brake line. Remove the caliper bracket bolts and remove the bracket from the knuckle.
3. 3

   Remove brake rotor
   Remove the rotor set screw if equipped. If rotor is stuck to the hub, use a rubber mallet to tap around the edge of the rotor to break it free. Do not strike the rotor face directly.
4. 4

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor electrical connector on the knuckle or in the wheel well area. Press the release tab and disconnect the connector. Remove the sensor mounting bolt and carefully extract the sensor from the knuckle. Note the sensor orientation for reinstallation.
5. 5

   Disconnect tie rod end
   Remove the cotter pin and castle nut from the tie rod end. Use a ball joint separator or pickle fork to separate the tie rod end from the knuckle. Be careful not to damage the tie rod boot. If the taper is stubborn, tap on the knuckle boss with a brass hammer while applying pressure with the separator tool.
6. 6

   Disconnect upper ball joint
   Remove the upper ball joint nut. Use a ball joint separator to break the taper between the upper control arm ball joint and the knuckle. Support the knuckle as you separate the joint to prevent it from dropping suddenly.
7. 7

   Disconnect lower ball joint
   Remove the lower ball joint nut. Use a ball joint separator to break the taper between the lower control arm ball joint and the knuckle. The knuckle assembly will now be free from the suspension.
8. 8

   Remove knuckle from CV axle
   Carefully pull the knuckle assembly away from the CV axle shaft. If the hub is tight on the axle splines, use a hub puller or slide hammer with appropriate adapters to press the axle out of the hub bearing. Do not strike the end of the axle shaft directly as this can damage the CV joint or axle threads. Once separated, carefully remove the knuckle assembly from the vehicle.
9. 9

   Prepare new knuckle assembly
   Clean all mating surfaces on the control arms and tie rod where they contact the new knuckle. Inspect the CV axle splines for damage or wear. Apply a thin coat of anti-seize compound to the axle splines. Install new ABS sensor O-ring if applicable. Compare new knuckle to old knuckle to verify correct part.
10. 10

    Install new knuckle onto CV axle
    Guide the new knuckle assembly onto the CV axle shaft, ensuring the splines engage properly. Push the knuckle onto the axle until it is fully seated. The axle should protrude through the hub bearing.
11. 11

    Connect lower ball joint
    Lift the knuckle and align the lower ball joint stud with the hole in the lower control arm. Install the new lower ball joint nut and tighten finger-tight. Do not torque at this stage.
12. 12

    Connect upper ball joint
    Align the upper ball joint stud with the hole in the upper control arm. Install the new upper ball joint nut and tighten finger-tight. Do not torque at this stage.
13. 13

    Connect tie rod end
    Insert the tie rod end stud into the knuckle. Install the new castle nut and tighten finger-tight. Do not torque at this stage.
14. 14

    Torque all suspension fasteners
    With the vehicle at ride height or with suspension loaded using a jack under the lower control arm, torque all fasteners to manufacturer specifications in this order: lower ball joint nut, upper ball joint nut, tie rod end nut. Install new cotter pin in tie rod castle nut and bend tabs to secure. Note: Torque specifications are not provided in the database; consult the official Rivian service manual for exact values.
15. 15

    Install axle nut
    Install the new axle nut onto the CV axle shaft. Torque to manufacturer specification using the same method to prevent hub rotation as during removal. Stake or install cotter pin as per OEM design.
16. 16

    Install ABS wheel speed sensor
    Clean the sensor bore in the knuckle with a wire brush. Apply a thin coat of dielectric grease to the new O-ring. Insert the ABS sensor into the knuckle, ensuring proper orientation. Install the sensor mounting bolt and tighten securely. Reconnect the electrical connector until it clicks.
17. 17

    Reinstall brake components
    Install the brake rotor onto the hub. Install the rotor set screw if equipped. Mount the caliper bracket to the knuckle with new bolts if specified. Install the brake caliper over the rotor and secure with caliper bolts. Check brake pad wear and replace if necessary.

Reassembly

1. Install wheel and tire assembly, hand-tighten lug nuts in star pattern
2. Lower vehicle to ground and torque lug nuts to specification in star pattern
3. Reconnect 12V auxiliary battery negative terminal
4. Start vehicle and verify no warning lights related to ABS or traction control
5. Pump brake pedal several times to restore proper brake pedal feel
6. Check brake fluid level and top off with DOT 4 fluid if necessary

Verification

• Test drive vehicle in safe area at low speed and verify proper steering response and no unusual noises
• Verify ABS system is functioning by checking for warning lights on instrument cluster
• Perform steering wheel centered test to confirm tie rod adjustment is within acceptable range
• Schedule four-wheel alignment immediately after this repair, as suspension geometry has been altered
• Recheck all fastener torques after first 50-100 miles of driving
• Inspect for any brake fluid leaks around caliper connections

More procedures for this vehicle