This procedure covers the removal and replacement of the rear leaf spring assembly on a 2025 Rivian EDV 500 commercial delivery van.

Warnings

Tools required

Parts

• Rear leaf spring assembly × 1 — Use OEM specification for EDV 500
• Leaf spring shackle bushings × 2 — Use OEM specification
• Leaf spring front eye bushing × 1 — Use OEM specification
• U-bolt kit with nuts and washers × 1 — Use OEM specification
• Shackle mounting hardware × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect 12V auxiliary battery negative terminal
3. Raise vehicle on appropriate lift or use jack and safety stands rated for commercial vehicle weight
4. Remove rear wheel on the side being serviced
5. Spray all leaf spring mounting hardware with penetrating oil and allow to soak
6. Position hydraulic floor jack under rear axle housing near the spring being serviced to support axle weight
7. Take photos of spring orientation and shackle positioning for reference during reassembly

Procedure

1. 1

   Support rear axle assembly
   Position a hydraulic floor jack under the rear axle housing approximately 6 inches from the leaf spring mount. Raise jack until it just contacts the axle but does not lift it. Place an additional safety stand under the opposite side of the axle for stability. The axle must remain supported throughout the entire procedure.
2. 2

   Remove shock absorber lower mount
   Locate the rear shock absorber lower mounting bolt where it attaches to the axle bracket near the leaf spring. Remove the lower shock mounting bolt and nut. Swing the shock absorber up and secure it out of the way with a bungee cord or zip tie to prevent interference with spring removal.
3. 3

   Disconnect brake line brackets
   Identify any brake line or ABS sensor wire brackets attached to the leaf spring or axle that may restrict spring movement. Remove the bracket mounting fasteners and carefully reposition lines out of the work area. Do not disconnect brake lines or ABS connectors.
4. 4

   Remove U-bolts
   Remove the four nuts securing the two U-bolts that clamp the leaf spring to the axle pad. The U-bolts pass through the spring mounting plate on top of the spring and thread into the plate underneath the axle. Once nuts are removed, extract the U-bolts from the assembly. Note the orientation of any alignment dowels or spacer plates.
5. 5

   Remove rear shackle lower bolt
   At the rear of the leaf spring, locate the shackle assembly connecting the spring to the frame bracket. Remove the lower shackle bolt that passes through the rear eye of the leaf spring. You may need to use a pry bar to align the holes if the spring is under tension. Leave the upper shackle bolt in place for now.
6. 6

   Remove front spring mount bolt
   At the front of the leaf spring, remove the through-bolt that passes through the front spring eye and the frame mounting bracket. This is typically the largest diameter bolt in the assembly. Support the spring with your hand or a helper as you remove this bolt, as the spring may shift once released.
7. 7

   Lower axle to release spring tension
   Slowly and carefully lower the hydraulic jack supporting the axle approximately 3-4 inches. This relieves remaining tension on the leaf spring. Monitor the spring as you lower the axle to ensure it does not bind or catch on any components.
8. 8

   Remove leaf spring assembly
   With the axle lowered and spring tension relieved, maneuver the leaf spring assembly out from between the axle and frame. The rear end of the spring will still be connected to the upper shackle bolt. Once the spring is clear of the axle, remove the upper shackle bolt and completely remove the spring assembly from the vehicle. The spring is heavy; use proper lifting technique or have a helper assist.
9. 9

   Inspect and clean mounting surfaces
   With the spring removed, thoroughly inspect the axle spring pad, frame mounting brackets, and shackle brackets for damage, corrosion, or wear. Use a wire brush to clean all mounting surfaces and hardware threads. Inspect the removed spring for cracks, broken leaves, or separation. Check all bushings in the spring eyes and shackles for deterioration.
10. 10

    Install new bushings
    If replacing bushings, press or drive out old bushings from the front spring eye, rear spring eye, and shackle assembly. Install new bushings ensuring they are fully seated and properly oriented. Some bushings may have offset holes or directional indicators. Apply a light coating of silicone grease to bushings to ease installation and prevent squeaking.
11. 11

    Position new leaf spring assembly
    Position the new or rebuilt leaf spring assembly into place. First, insert the front eye into the frame bracket and install the front mounting bolt finger-tight. Then align the rear eye with the shackle and install the lower shackle bolt finger-tight. The spring should hang naturally with no binding.
12. 12

    Raise axle to spring
    Using the hydraulic jack, carefully raise the rear axle up to meet the leaf spring. Align the axle spring pad with the center of the leaf spring pack. The spring center bolt should seat into the locating hole in the axle pad. Ensure any alignment dowels or spacer plates are in their correct positions.
13. 13

    Install U-bolts and mounting plate
    Position the U-bolt mounting plate on top of the spring and insert the U-bolts down through the plate, around the axle, and through the bottom mounting plate. Thread all four U-bolt nuts onto the U-bolts and tighten them in a crisscross pattern incrementally. Since no torque specifications are provided in the database, tighten to manufacturer specifications found in the vehicle service manual or on the replacement parts documentation.
14. 14

    Torque all spring mounting hardware
    With the axle at ride height and all components properly positioned, torque all mounting hardware. Torque the front spring eye bolt, both shackle bolts, and U-bolt nuts to manufacturer specifications. Tighten all fasteners with the vehicle at normal ride height to prevent bushing binding. Since no torque specifications are in the database, refer to OEM service manual or replacement parts documentation for correct values.
15. 15

    Reconnect components and finalize
    Reinstall the shock absorber lower mounting bolt and torque to specification. Reattach all brake line brackets and ABS sensor wire brackets removed earlier. Remove the hydraulic jack and safety stand from under the axle. Install the rear wheel and torque lug nuts to specification. Lower the vehicle to the ground.

Reassembly

1. All leaf spring mounting hardware should be torqued with the vehicle at ride height to prevent bushing preload and premature wear
2. Apply anti-seize compound to all bolt threads during reassembly to facilitate future service
3. Do not reuse U-bolts if they show any signs of thread damage or stretching
4. Ensure brake lines and ABS wiring have adequate clearance from the spring and suspension components throughout full travel

Verification

• Reconnect the 12V auxiliary battery and verify no electrical faults are present
• Bounce each corner of the vehicle to settle the suspension and verify proper spring seating
• Perform a visual inspection underneath to confirm all mounting hardware is properly installed and torqued
• Test drive the vehicle at low speed and listen for any unusual noises from the rear suspension
• After 50-100 miles of driving, re-check all leaf spring mounting hardware torque specifications
• Verify proper vehicle ride height and alignment; schedule four-wheel alignment if ride height has changed significantly

More procedures for this vehicle