This procedure covers the removal and replacement of the front radius arm on a 2025 Rivian EDV 500 commercial delivery van with dual motor AWD configuration.

Warnings

Tools required

Parts

• Radius arm assembly × 1 — Use OEM Rivian specification
• Radius arm mounting bolts/nuts × 1 — Use OEM specification - often single-use
• Radius arm bushings (if not included with arm) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes for system capacitors to discharge
4. If equipped, disable high-voltage system using service disconnect in appropriate location per Rivian service procedures
5. Loosen front wheel lug nuts while vehicle is on ground
6. Raise front of vehicle using floor jack at designated lift point
7. Support vehicle securely on jack stands at frame rails - verify stability before proceeding
8. Remove front wheel on affected side
9. Apply penetrating oil to all radius arm mounting fasteners and allow to soak
10. Document suspension ride height or mark positions for reference during reassembly

Procedure

1. 1

   Support suspension assembly
   Position a transmission jack or adjustable suspension support under the lower control arm near the radius arm mounting point. Raise slightly to take up weight of suspension but do not lift vehicle. This prevents sudden dropping when radius arm is disconnected.
2. 2

   Remove front radius arm to frame mounting bolt
   Locate the forward mounting point where radius arm connects to the frame rail. Remove the through-bolt and nut securing the radius arm front bushing to the frame bracket. This may require a long breaker bar due to tight installation. Note the orientation of any washers or spacers for reinstallation.
3. 3

   Disconnect radius arm from lower control arm or knuckle
   Locate the rear mounting point of the radius arm at the lower control arm or steering knuckle assembly. Remove the bolt(s) securing the radius arm rear bushing mount. On some configurations, this may involve removing a through-bolt; on others, it may be bolted to a bracket. Support the arm as you remove the final fastener.
4. 4

   Remove any interfering brake lines or wiring
   Inspect for any brake lines, ABS sensor wiring, or other components attached to or routed near the radius arm. Carefully unbolt or unclip these components, supporting them with mechanics wire to prevent strain. Do not allow brake lines to hang unsupported or kink.
5. 5

   Extract radius arm from vehicle
   With all fasteners removed and components clear, maneuver the radius arm out from its mounting location. This may require rotating or angling the arm to clear frame rails, control arms, or the front differential. Lower the suspension support jack slightly if needed for clearance, but maintain control of the suspension.
6. 6

   Inspect mounting points and bushings
   Examine the frame brackets and control arm mounting points for cracks, elongation, or damage. Check condition of bushing bores. Inspect the removed radius arm bushings for uneven wear, cracking, or separation - this may indicate other suspension issues. Clean all mounting surfaces with a wire brush and remove any corrosion or debris.
7. 7

   Prepare new radius arm
   Unpack the new radius arm assembly and verify it matches the removed part in length, bushing configuration, and mounting points. If bushings are serviceable separately, ensure they are properly installed and oriented in the new arm. Apply a light coating of anti-seize to the outer shell of the bushings where they contact metal brackets.
8. 8

   Install new radius arm into position
   Maneuver the new radius arm into the vehicle, positioning it approximately where it will mount. Align the front bushing with the frame bracket first. You may need to raise or lower the suspension support jack to align mounting holes. Use a pry bar if necessary to align holes, but do not force the arm into position if significant effort is required - check for clearance issues.
9. 9

   Install front mounting bolt
   Insert the front mounting through-bolt through the radius arm bushing and frame bracket. Install any washers or spacers in their original positions. Thread the nut onto the bolt but only hand-tighten at this stage. Do not torque suspension fasteners until vehicle is at ride height with weight on suspension.
10. 10

    Connect rear mounting point
    Align the rear radius arm bushing with its mounting location at the lower control arm or knuckle assembly. Adjust the suspension support jack height as needed to align holes perfectly. Install the rear mounting bolt(s) and hardware, again only hand-tightening. Apply thread locker to fasteners as specified in service manual.
11. 11

    Reinstall brake lines and wiring
    Reattach any brake lines, ABS sensor wiring, or other components that were removed for clearance. Ensure proper routing with no contact points that could cause chafing. Use new clips if original clips were damaged during removal. Verify no components are stretched or kinked.
12. 12

    Lower vehicle to load suspension
    Remove jack stands and carefully lower the vehicle until the suspension is at normal ride height with full vehicle weight on the wheels, but keep the floor jack positioned for safety. This loads the suspension bushings in their normal operating position before final torque is applied. Roll vehicle back and forth a few feet to settle suspension.
13. 13

    Torque all radius arm fasteners
    With suspension at ride height, torque the front radius arm mounting bolt to frame specification, followed by the rear mounting bolt(s) to control arm or knuckle. Since no torque specifications are available in the database, consult the Rivian service manual for exact values. Typically these fasteners are in the 100-150 ft-lb range for commercial vehicles but MUST be verified. Check that all fasteners are properly seated and torqued.
14. 14

    Reinstall wheel and final checks
    Install the wheel and torque lug nuts to specification in a star pattern. Remove floor jack and lower vehicle completely. Reconnect 12V battery. Re-enable high-voltage system if it was disabled. Perform a visual inspection underneath to verify all components are properly installed and nothing was left disconnected.

Reassembly

1. Always torque suspension fasteners with vehicle at ride height to prevent bushing bind
2. Verify all brake lines and ABS wiring are properly secured and routed clear of moving suspension components
3. Double-check that all fasteners have been torqued and none were left hand-tight
4. Ensure no tools or parts were left in the wheel well or under the vehicle

Verification

• Test drive vehicle at low speed in a safe area and listen for any unusual noises from the suspension
• Check for abnormal handling, pulling to one side, or vibration that was not present before repair
• Perform a visual inspection after test drive to verify all fasteners remain tight and no leaks are present
• Schedule four-wheel alignment as soon as possible - radius arm replacement will affect toe, caster, and potentially camber settings
• Re-check torque on all radius arm fasteners after 50-100 miles of driving

More procedures for this vehicle