Knuckle/Spindle - Rear

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

Warnings

Tools required

Parts

• Rear knuckle/spindle assembly × 1 — Use OEM specification
• Hub and bearing assembly (if integrated) × 1 — Use OEM specification
• Lower ball joint (if separate) × 1 — Use OEM specification
• Axle nut × 1 — Use OEM specification - single use
• Control arm mounting hardware × 1 — Use OEM specification
• Tie rod end (if reusing, inspect carefully) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks at front wheels
3. Verify high-voltage system is in service mode or disabled per manufacturer guidelines
4. Loosen rear wheel lug nuts while vehicle is on ground
5. Loosen but do not remove the rear axle nut (if equipped with axle shaft to hub)
6. Raise vehicle and support securely on jack stands at manufacturer-specified lift points
7. Remove rear wheel completely
8. Apply penetrating oil to all suspension fasteners that will be removed

Procedure

1. 1

   Remove brake caliper assembly
   Remove the brake caliper mounting bolts and carefully lift the caliper off the rotor. Support the caliper with a wire or bungee cord to avoid stressing the brake hose. Do not let the caliper hang by the brake line.
2. 2

   Remove brake rotor
   Remove any rotor retaining screws if present. If rotor is stuck due to corrosion, use a plastic hammer to tap around the outer edge to break it free. Slide the rotor off the hub.
3. 3

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor connector at the knuckle or nearby mounting point. Disconnect the electrical connector and carefully unclip or unbolt the sensor from the knuckle. Note routing for reinstallation.
4. 4

   Remove axle nut and separate axle from hub
   Fully remove the rear axle nut (already loosened during preparation). If the axle is splined into the hub, use a hub puller or slide hammer with appropriate adapters to press or pull the axle shaft out of the hub bearing. The shaft may be tight; apply steady pressure and avoid damaging the threads.
5. 5

   Disconnect upper control arm or strut mounting
   Depending on the EDV 500 rear suspension design, remove the upper control arm-to-knuckle bolt or the strut-to-knuckle bolts. Support the knuckle assembly with a floor jack to prevent it from falling when fasteners are removed.
6. 6

   Disconnect lower control arm
   Remove the lower control arm-to-knuckle bolt or ball joint pinch bolt. If a ball joint is pressed into the knuckle, use a ball joint separator or pickle fork to break the taper. Be careful not to damage the control arm if it is being reused.
7. 7

   Disconnect tie rod or trailing arm (if applicable)
   If the rear knuckle has a tie rod, camber link, or trailing arm connection, remove the mounting nut and use a ball joint separator to disconnect. Mark orientation and position if adjustable for alignment reference.
8. 8

   Remove knuckle assembly
   With all connections disconnected, carefully maneuver the knuckle assembly away from the vehicle. The hub bearing may be pressed or bolted into the knuckle. If the bearing is integrated, the entire assembly is replaced. If separate, press out the old bearing and hub.
9. 9

   Inspect and prepare new knuckle
   Inspect all mounting points on the new knuckle for debris or damage. If the hub bearing is separate, press the new bearing into the knuckle according to manufacturer specifications, ensuring it is seated fully and squarely. Clean all mating surfaces with a wire brush.
10. 10

    Install new knuckle to suspension
    Position the new knuckle assembly into place, aligning it with the upper and lower control arm mounting points. Install fasteners hand-tight initially. Ensure the knuckle is properly oriented and the splines or mounting surfaces are clean.
11. 11

    Reconnect control arms and suspension links
    Install and hand-tighten all control arm bolts, ball joint fasteners, and any tie rod or trailing arm connections. Ensure tapered ball joints are properly seated in their bores before tightening pinch bolts or castle nuts.
12. 12

    Install axle shaft into hub
    Carefully insert the axle shaft through the hub bearing, ensuring splines align properly. Avoid cross-threading or forcing. Install the new axle nut hand-tight (do not torque yet).
13. 13

    Reinstall ABS sensor and brake components
    Reconnect the ABS wheel speed sensor to the knuckle and plug in the electrical connector. Install the brake rotor onto the hub. Reinstall the brake caliper and secure with mounting bolts.
14. 14

    Torque all fasteners to specification
    Using a torque wrench, tighten all suspension and knuckle fasteners to manufacturer specifications in the proper sequence. Torque the axle nut to specification while the vehicle is still supported and the wheel is reinstalled (to prevent hub rotation). Note: Since no torque specifications are provided in the database, consult the Rivian service manual for exact values.

Reassembly

1. Reinstall the rear wheel and hand-tighten lug nuts
2. Lower the vehicle to the ground
3. Torque wheel lug nuts to specification in a star pattern
4. Verify brake pedal is firm before moving vehicle (pump brakes if necessary)
5. Check brake fluid level and top off with DOT 4 if needed due to caliper repositioning

Verification

• Test drive the vehicle at low speed in a safe area to verify no unusual noises or vibrations from the rear suspension
• Check for proper brake function and ABS operation
• Inspect all fasteners for proper torque and security
• Schedule a four-wheel alignment as soon as possible to ensure proper handling and tire wear
• Re-verify all fastener torques after 50-100 miles of driving

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