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

Warnings

Tools required

Parts

• Lower control arm × 1 — Use OEM specification
• Lower ball joint fastener/nut (if not reusable) × 1 — Use OEM specification
• Control arm bushing bolts (if not reusable) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V service battery (located in front compartment) and wait 2 minutes
3. Loosen wheel lug nuts while vehicle is on the ground
4. Raise vehicle using floor jack at designated front lift point
5. Secure vehicle on jack stands rated for at least 7,000 lbs capacity
6. Remove wheel and tire assembly
7. Apply penetrating oil to all control arm fasteners and allow to soak for 10-15 minutes

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the suspension load. Raise jack until it just makes contact and slightly compresses the suspension. This prevents the suspension from dropping when the control arm is disconnected.
2. 2

   Disconnect the stabilizer bar link
   Locate the stabilizer bar end link connection to the lower control arm. Hold the ball stud with a wrench to prevent spinning, then remove the retaining nut. Detach the stabilizer link from the control arm and move it aside.
3. 3

   Remove the lower ball joint pinch bolt or castle nut
   Locate the lower ball joint connection at the steering knuckle. Remove the castle nut or pinch bolt securing the ball joint to the knuckle. If equipped with a castle nut, remove the cotter pin first.
4. 4

   Separate the ball joint from the knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the lower ball joint stud from the steering knuckle. Apply force gradually to avoid damaging the knuckle or surrounding components. Once separated, support the knuckle and brake assembly to prevent strain on brake hoses and ABS wiring.
5. 5

   Mark the control arm position
   Before removing the control arm pivot bolts, mark the position of any alignment adjustment cams or shims with paint or a marker. This helps restore approximate alignment during reassembly and reduces post-repair alignment time.
6. 6

   Remove the front control arm pivot bolt
   Locate the front mounting bolt securing the control arm to the subframe or crossmember. Support the control arm with the jack while removing this bolt. Use a breaker bar if necessary. Remove the bolt completely and note the orientation of any washers or bushings.
7. 7

   Remove the rear control arm pivot bolt
   Locate and remove the rear mounting bolt securing the control arm to the subframe. This bolt may be longer and may pass through the subframe. Carefully lower the jack while guiding the control arm away from the mounting points.
8. 8

   Remove the lower control arm
   With both pivot bolts removed and the ball joint disconnected, carefully lower the control arm from the vehicle. Note the position of any spacers, washers, or alignment shims for reinstallation. Inspect the removed control arm for the cause of failure (bent, cracked, or worn bushings).
9. 9

   Clean mounting surfaces
   Use a wire brush to clean the control arm mounting points on the subframe. Remove any rust, debris, or corrosion. Inspect the subframe mounting points for damage or elongated bolt holes that would indicate structural issues.
10. 10

    Install the new lower control arm
    Position the new control arm into place, aligning the bushing mounting points with the subframe brackets. Use the floor jack to support the control arm at the correct height. Ensure any alignment marks or shims are positioned as noted during disassembly.
11. 11

    Install pivot bolts finger-tight
    Insert the front and rear pivot bolts through the control arm bushings and subframe brackets. Install bolts with any washers in their original orientation. Thread nuts on finger-tight only at this stage. Do not torque until the vehicle is at ride height with weight on the suspension.
12. 12

    Connect the ball joint to the knuckle
    Raise the control arm using the floor jack to align the ball joint stud with the hole in the steering knuckle. Insert the stud into the knuckle and install the castle nut or pinch bolt. Tighten the fastener to specification (torque specs not available - consult service manual). Install new cotter pin if equipped with castle nut.
13. 13

    Reconnect the stabilizer bar link
    Align the stabilizer bar end link with the connection point on the lower control arm. Install the retaining nut while holding the ball stud with a wrench. Tighten to specification per service manual.
14. 14

    Torque pivot bolts at ride height
    Lower the vehicle until the tires just touch the ground or use the jack to simulate ride height loading on the suspension. This ensures bushings are not pre-loaded. Torque the front and rear control arm pivot bolts to manufacturer specification (consult service manual as torque specs not provided). Remove jack from under control arm.
15. 15

    Reinstall wheel and perform final checks
    Install the wheel and tire assembly. Torque lug nuts to specification in a star pattern. Remove jack stands and lower vehicle completely. Reconnect 12V service battery. Bounce the front suspension several times to settle components.

Reassembly

1. Ensure all fasteners are tightened to proper specifications
2. Verify no tools or parts were left in the wheel well
3. Check that brake lines and ABS wiring are properly routed and secured
4. Confirm stabilizer bar link is properly connected

Verification

• Test drive vehicle at low speed in a safe area and listen for unusual noises from the suspension
• Check for proper steering response and unusual pulling
• Schedule a four-wheel alignment immediately after repair - control arm replacement will affect camber, caster, and toe settings
• After 50-100 miles, re-check all control arm fastener torque values
• Verify no unusual tire wear patterns develop after alignment

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