This procedure covers the removal and replacement of leaf spring bushings on the 2025 Rivian EDV 500, including suspension disassembly and bushing press-out/press-in operations.

Warnings

Tools required

Parts

• Leaf spring bushing kit (front or rear as needed) × 2 — Use OEM specification
• Leaf spring shackle bushings (if applicable) × 2 — Use OEM specification
• U-bolt lock nuts × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks at front wheels if servicing rear, or rear wheels if servicing front
3. Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
4. Engage high-voltage service disconnect according to manufacturer emergency response guide
5. Raise vehicle on lift or jack and support securely on rated axle stands at frame contact points
6. Remove wheel and tire assembly on side being serviced
7. Spray all suspension fasteners with penetrating lubricant and allow to soak for 10-15 minutes
8. Inspect leaf spring pack for cracks, damage, or separation before proceeding

Procedure

1. 1

   Support rear axle assembly
   Position hydraulic floor jack under rear axle housing near the leaf spring being serviced. Raise jack just enough to contact axle and take slight load off suspension, but do not lift vehicle. This maintains control of the axle during disassembly.
2. 2

   Disconnect shock absorber lower mount
   Locate the shock absorber lower mounting bolt at the axle bracket. Remove the lower shock mounting bolt and washer. Carefully push shock absorber up and out of the way. Support with mechanic wire if necessary to prevent strain on upper mount.
3. 3

   Remove U-bolt nuts and plate
   Remove the four U-bolt nuts securing the leaf spring to the axle housing. Note the orientation of the axle seat plate and any alignment marks. Remove the U-bolt plate and U-bolts. Set hardware aside and mark for replacement as these are typically one-time-use fasteners.
4. 4

   Remove rear shackle assembly
   If replacing rear spring eye bushing, remove the bolt and nut securing the rear shackle to the frame bracket. Then remove the bolt securing the shackle to the spring eye. Remove the shackle assembly. Inspect shackle bushings for wear and replace if needed.
5. 5

   Remove front spring mounting bolt
   Support the leaf spring with one hand or have an assistant hold it. Remove the bolt and nut securing the front spring eye to the front hanger bracket. The spring pack will now be free from the vehicle. Carefully lower the spring assembly and remove from under vehicle.
6. 6

   Inspect and clean spring eyes
   Place leaf spring assembly on clean workbench. Inspect spring eyes for cracks, elongation, or damage. Use wire brush to clean inside spring eyes and remove any rust, debris, or old bushing material. Check for adequate clearance for bushing removal tool.
7. 7

   Press out old bushings
   Using hydraulic press or leaf spring bushing press tool, position spring eye in press fixture. Select appropriate receiver cup size to support outer edge of spring eye. Use driver tool sized to old bushing outer diameter and press bushing straight out of spring eye. Repeat for opposite eye if servicing both ends. Ensure spring eye does not deform during pressing operation.
8. 8

   Clean and prepare spring eye bore
   Thoroughly clean inside bore of spring eye with wire brush and solvent to remove all old bushing material, rust, and debris. Inspect bore for damage or cracks. Apply thin coat of anti-seize compound to inside diameter of spring eye bore to prevent corrosion and facilitate future removal.
9. 9

   Press in new bushings
   Position new bushing at spring eye opening, ensuring bushing is square to bore. If bushing has flange, verify correct orientation per manufacturer specifications. Using hydraulic press with appropriately sized driver tool, press new bushing squarely into spring eye until fully seated and flush (or per specified depth). Press slowly and ensure bushing does not cock or bind. Repeat for opposite spring eye if applicable.
10. 10

    Reinstall leaf spring front mount
    With assistance or using jack to support spring, position leaf spring front eye into front hanger bracket. Insert front mounting bolt through bracket and spring eye bushing. Install washer and nut finger-tight. Do not fully torque at this time as suspension must be at ride height.
11. 11

    Reinstall rear shackle assembly
    If rear shackle was removed, install shackle to spring rear eye with bolt and nut, leaving finger-tight. Position shackle upper end to frame bracket and install mounting bolt and nut finger-tight. Verify shackle moves freely and is not binding.
12. 12

    Position axle and install U-bolts
    Raise hydraulic jack to position axle housing into proper alignment with leaf spring center bolt. Verify axle housing seats properly in spring with center bolt located in axle pad hole. Install new U-bolts over axle and through spring plate. Install spring plate and thread on new U-bolt nuts. Torque U-bolt nuts in cross pattern to manufacturer specification (torque spec not available - consult service manual).
13. 13

    Reconnect shock absorber
    Position shock absorber lower eye to axle mounting bracket. Install lower shock mounting bolt and nut. Torque to manufacturer specification (torque spec not available - consult service manual).
14. 14

    Torque suspension fasteners at ride height
    With vehicle still supported on axle stands, lower hydraulic jack to remove load from leaf spring. Reinstall wheel and tire assembly. Lower vehicle to ground so suspension is at normal ride height with full vehicle weight. Torque front spring eye bolt and rear shackle bolts to manufacturer specification (torque specs not available - consult service manual). This step is critical as leaf spring bushings must be torqued at ride height to prevent binding and premature wear.

Reassembly

1. All suspension fasteners must be torqued to specification with vehicle at ride height, not with suspension hanging
2. New U-bolt nuts should always be used and should not be reused
3. Verify shock absorber is not binding and has full range of motion
4. Reconnect high-voltage service disconnect per manufacturer procedure
5. Reconnect 12V battery negative terminal
6. Clear any diagnostic trouble codes using appropriate scan tool

Verification

• Verify all suspension mounting bolts are properly torqued at ride height
• Test drive vehicle on smooth road and verify no abnormal noise, vibration, or handling issues
• Perform visual inspection underneath vehicle for any loose hardware or leaking fluids
• Check leaf spring alignment and verify axle is properly centered in wheelwells
• After 50-100 miles of driving, re-torque U-bolt nuts and verify they have not loosened
• Verify vehicle tracking is straight and alignment is within specification (professional alignment recommended after suspension work)

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