This procedure covers the removal and replacement of a leaf spring shackle on the 2025 Rivian EDV 500 electric delivery van, including suspension support and fastener replacement.

Warnings

Tools required

Parts

• Leaf spring shackle assembly × 1 — Use OEM specification
• Shackle mounting bolts × 2 — Use OEM specification
• Shackle bushings × 2 — Use OEM specification
• Lock washers or locking nuts × 2 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks on front wheels
3. Power off the vehicle completely and remove the key fob from the cabin
4. Verify the high-voltage system is de-energized (consult owner's manual for indicator lights)
5. If shackle bolts are visibly corroded, apply penetrating oil and allow to soak for at least 30 minutes (preferably 24 hours)
6. Loosen rear wheel lug nuts while vehicle is still on the ground
7. Raise the rear of the vehicle using a floor jack at the designated jacking point on the frame
8. Install heavy-duty jack stands under the frame rails behind the area being serviced
9. Remove the rear wheel on the side requiring shackle replacement

Procedure

1. 1

   Support the rear axle
   Position a transmission jack or heavy-duty axle stand directly under the rear axle housing near the leaf spring. Raise it until it just makes contact with the axle, providing support but not lifting. This prevents the axle from dropping excessively when the shackle is removed and maintains control of the leaf spring tension.
2. 2

   Locate the leaf spring shackle
   Identify the leaf spring shackle at the rear mounting point of the leaf spring. The shackle connects the rear eye of the leaf spring to the frame bracket. Inspect the shackle, bushings, and mounting bolts for wear, corrosion, or damage to confirm replacement is necessary.
3. 3

   Remove the lower shackle bolt
   Using a socket and wrench, remove the lower shackle bolt that connects the shackle to the rear eye of the leaf spring. You may need to hold the bolt head with a wrench while turning the nut from the opposite side. If the bolt spins freely, use penetrating oil and apply heat carefully if necessary. Remove the bolt completely and set aside the hardware.
4. 4

   Remove the upper shackle bolt
   Remove the upper shackle bolt that connects the shackle to the frame bracket. This bolt typically passes through the frame mount and the shackle bushing. Support the shackle with one hand as you remove the final fastener to prevent it from falling. Remove the bolt and nut completely.
5. 5

   Remove the shackle assembly
   Extract the shackle assembly from between the frame bracket and leaf spring eye. If the shackle is seized or corroded in place, use a pry bar carefully to separate it from the mounting points. Inspect the frame bracket and leaf spring eye for damage or excessive wear.
6. 6

   Inspect and clean mounting surfaces
   Use a wire brush to clean the mounting surfaces on both the frame bracket and the leaf spring eye. Remove all rust, corrosion, and debris. Inspect the bolt holes in both the frame bracket and spring eye for elongation, cracks, or damage. If damage is found, further repair will be required before proceeding.
7. 7

   Prepare the new shackle assembly
   Unpack the new shackle assembly and verify it matches the original design. Install new bushings into the shackle eyes if they are not pre-installed. Apply a light coating of multi-purpose grease to the bushing surfaces and new bolt threads to prevent corrosion and aid in future removal.
8. 8

   Install the new shackle to the frame bracket
   Position the new shackle assembly into the frame bracket. Insert the upper shackle bolt through the frame bracket and shackle bushing. Start the nut on the bolt threads by hand but do not tighten completely at this stage. The shackle should pivot freely on the bolt.
9. 9

   Connect the shackle to the leaf spring
   Align the lower portion of the shackle with the rear eye of the leaf spring. You may need to use the transmission jack to slightly adjust the axle height to align the holes. Insert the lower shackle bolt through the spring eye and shackle bushing. Start the nut on the bolt threads by hand.
10. 10

    Torque the shackle fasteners
    Since manufacturer torque specifications are not available in the database, refer to the vehicle service manual or OEM documentation for exact torque values. Typically, leaf spring shackle bolts on commercial vehicles require 100-150 ft-lbs. Torque the upper frame bracket bolt first, then the lower spring eye bolt. Ensure the vehicle weight is resting on the suspension (lower from jack stands to load the suspension) before final torquing to prevent binding.
11. 11

    Verify shackle operation
    Check that the shackle pivots freely and is not binding. Visually inspect that both bolts are fully seated and that lock washers or locking nuts are properly engaged. Verify there is no interference between the shackle and surrounding components.

Reassembly

1. Reinstall the rear wheel and hand-tighten lug nuts
2. Carefully raise the vehicle with the floor jack and remove the transmission jack from under the axle
3. Remove the jack stands from under the frame
4. Lower the vehicle completely to the ground
5. Torque wheel lug nuts to manufacturer specification in a star pattern
6. Remove wheel chocks

Verification

• Visually inspect the installed shackle to ensure all fasteners are tight and properly torqued
• Bounce the rear of the vehicle several times to settle the suspension and verify no unusual noises from the shackle area
• Take a short test drive at low speed and listen for any clunking, squeaking, or unusual noises from the rear suspension
• Re-check shackle bolt torque after 50-100 miles of driving
• Inspect for any fluid leaks near the work area (though this job should not affect any fluid systems)
• Verify the vehicle tracks straight and there is no abnormal handling behavior

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