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

Warnings

Tools required

Parts

• Rear lower control arm × 1 — Use OEM specification
• Control arm mounting bolts/hardware kit × 1 — Use OEM specification
• Ball joint castle nut (if applicable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks at front wheels
3. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
4. Disconnect 12V auxiliary battery to disable air suspension if equipped
5. Raise vehicle using floor jack at manufacturer-specified lift points
6. Support vehicle securely on jack stands at frame-rated support points
7. Remove rear wheel on affected side
8. Spray penetrating oil on all control arm fasteners and allow to soak

Procedure

1. 1

   Support the rear suspension
   Position a floor jack under the rear knuckle assembly or lower suspension arm to support the weight and maintain suspension geometry. Raise slightly to take load off the control arm but do not lift the vehicle. This prevents sudden dropping when fasteners are removed.
2. 2

   Disconnect stabilizer bar link (if equipped)
   If the stabilizer bar link connects to the lower control arm, remove the nut securing the link to the control arm. Hold the ball stud with a wrench to prevent spinning. Set hardware aside for reinstallation.
3. 3

   Remove control arm-to-knuckle connection
   Locate the ball joint or bushing connection at the outer end of the control arm where it connects to the rear knuckle. Remove the retaining nut. If a ball joint type, use a ball joint separator tool to break the taper connection. Strike the knuckle boss sharply with a hammer while applying separator pressure if needed. Do not damage the knuckle or surrounding components.
4. 4

   Mark alignment position
   Before removing frame-side mounting bolts, use a paint pen or scribe to mark the position of any adjustment cams, eccentric washers, or shims relative to the mounting bracket. This will aid in initial alignment during reinstallation.
5. 5

   Remove front control arm mounting bolt
   Locate the forward mounting point where the control arm attaches to the chassis or subframe. Remove the bolt and any washers or bushings. Note the orientation of any eccentric washers or cam bolts. The bolt may require significant force due to thread-locking compound. Support the control arm to prevent it from dropping.
6. 6

   Remove rear control arm mounting bolt
   Remove the rear mounting bolt securing the control arm to the chassis or subframe. Again note the position of any adjustment hardware. The control arm may now be free to move significantly, so maintain support with your hand or the jack.
7. 7

   Remove the lower control arm
   Carefully maneuver the control arm out from its mounting position. It may be necessary to pivot or angle the arm to clear the knuckle, brake components, or motor assembly. Lower the supporting jack slightly if needed to gain clearance. Inspect the removed arm for damage, wear, or the reason for replacement.
8. 8

   Inspect mounting points and bushings
   Clean all mounting surfaces on the chassis with a wire brush. Inspect the mounting brackets for cracks, elongated holes, or damage. Check the condition of bushings in the chassis mounting points. Inspect the ball joint seat on the knuckle for damage or excessive wear.
9. 9

   Prepare new control arm
   Unpack the new control arm and verify it matches the removed part. Check that all bushings are properly seated and the ball joint (if integrated) moves freely without binding. Apply a light coat of anti-seize to bolt threads unless they are pre-coated with thread locker.
10. 10

    Install new control arm to chassis
    Position the new control arm into the mounting brackets. Install the front and rear mounting bolts with any washers, cams, or shims in their original orientation per the alignment marks made earlier. Thread bolts by hand initially to ensure proper thread engagement. Do not fully tighten yet—leave bolts snug but allow movement for adjustment.
11. 11

    Connect control arm to knuckle
    Raise or lower the support jack to align the control arm ball joint or mounting point with the knuckle. Insert the ball joint stud into the knuckle and install the retaining nut. If using a castle nut and cotter pin, align the castle slots with the cotter pin hole. Tighten the nut to specifications per manufacturer guidelines.
12. 12

    Reconnect stabilizer bar link
    If previously disconnected, reconnect the stabilizer bar link to the control arm. Install the nut and tighten while holding the ball stud to prevent spinning. Tighten to manufacturer specifications.
13. 13

    Torque all fasteners to specification
    With the suspension at ride height (jack supporting the knuckle at normal position), torque all control arm mounting bolts to the manufacturer's specifications using a calibrated torque wrench. Torque specifications are critical for proper bushing life and suspension geometry. Torque the knuckle connection and stabilizer link as well. Since specific torque values are not provided in the database, consult the Rivian service manual for exact specifications before proceeding.
14. 14

    Remove supports and reinstall wheel
    Lower and remove the floor jack from under the suspension. Reinstall the rear wheel and hand-tighten all lug nuts in a star pattern. Lower the vehicle to the ground and torque lug nuts to specification (typically 150-175 lb-ft for commercial vehicles, but verify with Rivian specifications).

Reassembly

1. Reconnect the 12V auxiliary battery
2. If equipped with air suspension, allow system to re-pressurize and cycle through self-leveling routine
3. Repeat procedure on opposite side if replacing both control arms
4. Test drive vehicle at low speed in a safe area to verify no unusual noises or handling issues before proceeding to alignment shop

Verification

• Verify all fasteners are torqued to specification and no hardware was left loose
• Check that the ball joint connection is secure with no play or movement
• Bounce each corner of the vehicle to ensure suspension operates normally without binding or noise
• Inspect for proper wheel clearance and verify no components contact the tire during suspension travel
• Schedule a four-wheel alignment immediately—improper alignment can cause tire wear and handling issues
• After alignment, test drive and verify straight-line tracking and normal handling characteristics

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