This procedure covers the replacement of the leaf spring U-bolt kit on the 2025 Rivian EDV 500, securing the axle to the leaf spring assembly.

Warnings

Tools required

Parts

• Leaf spring U-bolt kit (includes U-bolts, nuts, and washers) × 1 — Use OEM specification
• Anti-seize compound × 1 — High-temperature rated

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks in front of the wheels not being serviced
3. Disconnect 12V battery negative terminal and wait 2 minutes for system discharge
4. Loosen lug nuts on the wheel(s) where U-bolts will be replaced while vehicle is on ground
5. Raise vehicle with floor jack at manufacturer-specified jacking points
6. Support vehicle securely on jack stands rated for the vehicle weight
7. Remove wheel(s) to access suspension components
8. Spray penetrating oil on U-bolt threads and allow to soak for 10-15 minutes
9. Position hydraulic transmission jack or axle stand under the axle housing for support

Procedure

1. 1

   Support the axle assembly
   Position a hydraulic transmission jack or adjustable axle stand directly under the axle housing near the U-bolt location. Raise the jack slightly to take up any slack and support the weight of the axle, but do not lift the vehicle. This prevents the axle from dropping when U-bolts are removed.
2. 2

   Remove existing U-bolt nuts
   Using a socket and breaker bar (or impact wrench), remove the nuts from the existing U-bolts. Remove nuts in a criss-cross pattern to prevent binding. Keep track of washers and hardware orientation for reference during reassembly.
3. 3

   Remove old U-bolts and bottom plate
   Once nuts are removed, extract the U-bolts from the spring plate assembly. Remove the bottom plate (saddle) that sits between the U-bolts and the axle. Inspect the plate for wear, damage, or deformation. If damaged, it must be replaced.
4. 4

   Inspect mounting surfaces
   Thoroughly inspect the leaf spring mounting surface, axle housing contact area, and spring seat for damage, cracks, or excessive wear. Check leaf spring condition for broken leaves or separation. Any damage to these components requires replacement before proceeding.
5. 5

   Clean all mounting surfaces
   Use a wire brush to clean the axle housing mounting surface, leaf spring top surface, and spring plate surfaces. Remove all rust, debris, and old thread compound. Ensure surfaces are clean and flat for proper seating of new components.
6. 6

   Position bottom plate on axle
   Place the bottom plate (saddle) from the new U-bolt kit onto the axle housing, ensuring it is properly centered and seated in the correct orientation. The plate should fit the axle housing contour precisely.
7. 7

   Align axle with leaf spring
   Using the transmission jack, carefully adjust the axle height and position to align it properly with the leaf spring. The spring center bolt should align with the locating hole in the bottom plate. Ensure the axle is positioned at the correct ride height and not twisted.
8. 8

   Install new U-bolts
   Insert the new U-bolts from the U-bolt kit down through the spring plate, around the axle housing, and through the holes in the bottom plate. Ensure U-bolts are fully seated and threads protrude sufficiently through the bottom plate for nut installation.
9. 9

   Install washers and nuts
   Place new washers (if included in kit) onto the U-bolt threads, followed by the new nuts. Thread nuts onto all U-bolts by hand until they contact the washers. Do not tighten yet. Ensure all threads engage properly and nuts turn smoothly.
10. 10

    Initial torque of U-bolt nuts
    Apply anti-seize compound to threads if recommended by manufacturer. Using a torque wrench, tighten U-bolt nuts in a criss-cross pattern to approximately 50% of final torque specification. This ensures even seating of components. Without manufacturer torque specs, consult a Rivian service manual or dealer for proper values before proceeding.
11. 11

    Final torque of U-bolt nuts
    After initial torque, proceed with final torque in a criss-cross pattern. Since no torque specifications are provided in the database, you must obtain the correct torque value from Rivian service documentation before completing this step. Typical leaf spring U-bolt torque ranges from 90-150 ft-lbs, but this must be verified for this specific vehicle.
12. 12

    Remove axle support
    Carefully lower and remove the hydraulic transmission jack or axle stand from under the axle housing. Verify that the axle remains properly seated on the leaf spring and that all components are secure.
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the wheel(s) and hand-tighten lug nuts in a star pattern. Lower vehicle from jack stands and remove stands. Lower vehicle completely to the ground. Torque lug nuts to manufacturer specification (typically 150 ft-lbs for this vehicle class) in a star pattern.

Reassembly

1. Reconnect 12V battery negative terminal
2. After driving 50-100 miles, re-torque U-bolt nuts to verify they have maintained proper torque specification
3. Inspect U-bolt installation after first 500 miles and periodically thereafter as part of regular maintenance

Verification

• Verify all U-bolt nuts are torqued to specification using a torque wrench
• Visually inspect that the axle is properly seated on the leaf spring with no gaps
• Confirm the bottom plate is centered and flush against the axle housing
• Check that all U-bolt threads protrude beyond the nuts by at least 2-3 threads
• Perform a test drive at low speed and verify no unusual noises, vibrations, or handling issues
• After test drive, re-check all U-bolt torque values to ensure they have not loosened

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