This procedure covers the removal and replacement of the front lower control arm on a 2025 Rivian EDV 500 electric delivery van with dual motor AWD.

Warnings

Tools required

Parts

• Front lower control arm × 1 — Use OEM specification
• Control arm to frame mounting bolts × 2 — Use OEM specification
• Ball joint castle nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park the vehicle on a level, solid surface and engage the parking brake
2. Place wheel chocks behind the rear wheels
3. Disable the high-voltage system following manufacturer procedures
4. Loosen the front wheel lug nuts while the vehicle is still on the ground
5. Raise the front of the vehicle with a floor jack and support securely on jack stands at the manufacturer-recommended lift points
6. Remove the front wheel on the side being serviced
7. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove the front wheel
   With the lug nuts already loosened, completely remove the lug nuts and take off the front wheel. Set the wheel aside in a safe location.
2. 2

   Support the lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the weight of the knuckle and suspension. Raise the jack just enough to slightly compress the suspension and relieve tension on the control arm fasteners.
3. 3

   Disconnect the stabilizer bar link
   Locate the stabilizer bar end link connection to the lower control arm. Remove the nut securing the end link to the control arm. Use a wrench on the ball joint stud to prevent spinning if necessary. Disconnect the link from the control arm.
4. 4

   Remove the ball joint cotter pin and castle nut
   Locate the ball joint where the lower control arm connects to the steering knuckle. Remove the cotter pin from the castle nut. Using a socket and breaker bar, remove the castle nut from the ball joint stud. Keep the nut if it will be reused.
5. 5

   Separate the ball joint from the knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the lower control arm ball joint from the steering knuckle. Position the tool between the control arm and knuckle, then strike or press to break the taper fit. Avoid damaging the ball joint boot if the control arm is being reused.
6. 6

   Remove the front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the subframe or crossmember. This is typically the forward-most attachment point. Using a socket and breaker bar, remove the bolt completely. Support the control arm to prevent it from dropping.
7. 7

   Remove the rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the subframe or crossmember. This is typically at the rearward bushing location. Remove the bolt completely while supporting the control arm weight.
8. 8

   Remove the lower control arm
   With all fasteners removed and the ball joint separated, carefully maneuver the lower control arm out of the suspension assembly. You may need to angle or rotate the arm to clear other components. Inspect the mounting areas on the frame for damage or excessive rust.
9. 9

   Prepare the new control arm
   Inspect the new lower control arm to ensure it matches the removed part. Check that ball joint boots are intact and bushings are properly installed. Apply a light coat of anti-seize to the bolt threads and mounting surfaces.
10. 10

    Install the new control arm
    Position the new lower control arm into the mounting location. Align the bushing holes with the frame mounting points. Insert the rear mounting bolt first, threading it by hand but do not fully tighten yet.
11. 11

    Install the front mounting bolt
    Align the front bushing with its frame mount and insert the front mounting bolt. Thread it by hand to ensure proper alignment. With both bolts started, verify the control arm is properly seated in all mounting locations.
12. 12

    Connect the ball joint to the knuckle
    Raise the floor jack under the control arm to align the ball joint stud with the hole in the steering knuckle. Guide the stud through the knuckle. Install the castle nut and tighten it to specification (refer to service manual for exact torque value).
13. 13

    Install the cotter pin
    Align the castle nut slots with the hole in the ball joint stud. If alignment is off, tighten the nut slightly more (never loosen). Insert a new cotter pin through the stud hole and bend the ends to secure it properly.
14. 14

    Reconnect the stabilizer bar link
    Reconnect the stabilizer bar end link to the lower control arm. Install the nut and tighten to specification. Use thread locker if specified by the manufacturer.
15. 15

    Torque all fasteners to specification
    With the suspension at normal ride height (accomplished by lowering the jack under the control arm to simulate vehicle weight), torque the front and rear control arm mounting bolts to the manufacturer specification. This is critical for proper bushing operation and longevity. Refer to the official Rivian service manual for exact torque values.

Reassembly

1. Reinstall the wheel and hand-tighten the lug nuts
2. Lower the vehicle until the tire just touches the ground, then torque the lug nuts to specification in a star pattern
3. Completely lower the vehicle and remove jack stands
4. Re-enable the high-voltage system following manufacturer procedures
5. Double-check that all fasteners have been properly tightened

Verification

• Test drive the vehicle at low speed in a safe area and listen for any unusual noises from the suspension
• Perform a steering test to ensure proper operation and no binding
• Verify no clunking or rattling sounds from the front suspension over bumps
• Schedule a professional wheel alignment as control arm replacement will affect suspension geometry
• After 50-100 miles of driving, re-check all fastener torque values to ensure nothing has loosened

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