Panhard Bar/Track Bar

This procedure covers the removal and replacement of the Panhard bar (track bar) on the 2025 Rivian EDV 500 Dual Motor AWD, which controls lateral axle movement and maintains proper rear suspension alignment.

Warnings

Tools required

Parts

• Panhard bar/track bar assembly × 1 — Use OEM specification
• Panhard bar mounting bolts × 2 — Use OEM specification
• Panhard bar bushings (if not included with bar) × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes for system capacitors to discharge
3. If equipped with air suspension, enter maintenance mode using vehicle service menu to exhaust air from system
4. Raise vehicle on lift or use heavy-duty jack and jack stands rated for commercial EV weight (minimum 4-ton capacity per stand)
5. Place jack stands under manufacturer-specified lift points on frame rails
6. Remove rear wheels for improved access to Panhard bar mounting points
7. Spray penetrating oil on all Panhard bar mounting bolts and allow to soak for 10-15 minutes

Procedure

1. 1

   Support the rear axle assembly
   Position a heavy-duty hydraulic jack with a wood block cushion under the center of the rear axle housing. Raise the jack until it just contacts the axle and supports its weight without lifting it. This prevents the axle from dropping or shifting when the Panhard bar is removed.
2. 2

   Locate Panhard bar mounting points
   Identify the Panhard bar running laterally across the rear suspension. One end mounts to the rear axle housing on the passenger side, and the other end mounts to a bracket on the driver side frame rail. Inspect both mounting points for corrosion or damage.
3. 3

   Remove axle-side mounting bolt
   Using a breaker bar and appropriate socket, loosen and remove the bolt securing the Panhard bar to the rear axle housing bracket on the passenger side. Support the bar with your hand as you remove the bolt completely. The bushing may stick in the mounting bracket.
4. 4

   Remove frame-side mounting bolt
   Move to the driver side frame rail mounting point. Using a breaker bar and socket, loosen and remove the bolt securing the Panhard bar to the frame bracket. The bar will now be free from the vehicle. Carefully lower and remove the Panhard bar assembly from the vehicle.
5. 5

   Inspect mounting brackets and bushings
   With the Panhard bar removed, thoroughly inspect both mounting brackets on the axle and frame for cracks, elongated holes, or damage. Check the removed bar's bushings for tears, deterioration, or excessive wear. Clean mounting surfaces with a wire brush to remove rust and debris.
6. 6

   Prepare new Panhard bar
   If installing a new bar, verify all bushings are properly installed and oriented correctly. Apply a light coating of anti-seize compound to the mounting bolt threads (avoid getting anti-seize on bolt heads or contact surfaces). Ensure the bar is the correct length and matches the removed component.
7. 7

   Position new Panhard bar
   Lift the new Panhard bar into position, aligning it with both the frame-side bracket (driver side) and axle-side bracket (passenger side). You may need to use a pry bar to gently shift the axle position to align the mounting holes. Ensure the bar orientation matches the original installation.
8. 8

   Install frame-side mounting bolt
   Insert the new or cleaned mounting bolt through the frame bracket and Panhard bar bushing on the driver side. Thread the nut onto the bolt by hand, but do not fully tighten yet. Leave the connection slightly loose to allow for alignment adjustment.
9. 9

   Install axle-side mounting bolt
   Insert the mounting bolt through the axle bracket and Panhard bar bushing on the passenger side. Thread the nut onto the bolt by hand. Again, do not fully tighten. Both ends should be loose enough to allow the bar to pivot slightly for proper alignment.
10. 10

    Load suspension to normal ride height
    With both bolts hand-tight, slowly raise the hydraulic jack under the axle until the suspension is at approximately normal ride height (simulate vehicle weight load). This ensures the bushings are not pre-loaded in a twisted position, which would cause premature wear.
11. 11

    Torque Panhard bar mounting bolts
    With the suspension at normal ride height, torque both Panhard bar mounting bolts to manufacturer specifications using a calibrated torque wrench. Since specific torque values are not provided in the database, consult the Rivian EDV 500 service manual for exact specifications (typically in the range of 100-150 lb-ft for commercial vehicle track bars, but verify before tightening).
12. 12

    Lower axle and remove jack
    Carefully lower the hydraulic jack from under the rear axle, allowing the suspension to settle. Remove the jack completely. Visually verify that the Panhard bar is properly seated in both mounting brackets and that there is no binding or unusual angles.
13. 13

    Reinstall rear wheels
    Reinstall both rear wheels, threading lug nuts by hand first. Torque lug nuts to Rivian specifications in a star pattern. Lower the vehicle completely to the ground.

Reassembly

1. Reconnect the 12V auxiliary battery negative terminal
2. If air suspension was placed in maintenance mode, exit maintenance mode and allow system to re-inflate to normal ride height
3. Clear any suspension-related fault codes using diagnostic tool if they appeared during the procedure

Verification

• Start the vehicle and verify no suspension warning lights are illuminated on the dashboard
• Perform a visual inspection underneath the vehicle to confirm both Panhard bar mounting bolts are secure and properly torqued
• Test drive the vehicle at low speed in a safe area, making gentle turns to verify proper rear axle tracking and no unusual noises
• Check for any lateral axle movement or clunking sounds during direction changes
• Schedule a four-wheel alignment to ensure proper rear axle centerline and thrust angle after Panhard bar replacement

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