Strut Assembly - Rear

This procedure covers the removal and replacement of the rear strut assembly on a 2025 Rivian EDV 500 electric delivery van, including disconnection of suspension components and installation of new strut assemblies.

Warnings

Tools required

Parts

• Rear strut assembly × 2 — Use OEM Rivian specification
• Strut upper mounting nuts × 1 — Use OEM specification
• Anti-seize compound × 1 — Copper or nickel-based

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks in front of front wheels
3. Disconnect 12V battery negative terminal and wait 2 minutes
4. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
5. Lift rear of vehicle using approved lift points per Rivian service manual
6. Support vehicle on jack stands rated for at least 4,000 lbs each side
7. Remove rear wheels completely
8. Spray penetrating oil on all strut mounting fasteners and allow to soak for 10-15 minutes
9. Photograph suspension geometry and component orientation for reassembly reference

Procedure

1. 1

   Access upper strut mounting area
   Open rear cargo doors or access panels to reach the upper strut tower mounting points inside the vehicle body. On the EDV 500, this typically requires removing interior trim panels or accessing through the cargo area. Remove any cargo area side panels that block access to the strut towers. The upper mounts are typically accessible from inside the cargo bay.
2. 2

   Support rear suspension
   Position a hydraulic jack under the rear lower control arm or axle assembly on the side being serviced. Raise jack just enough to take slight load off the strut, but do not lift the suspension. This prevents the suspension from dropping when strut is disconnected and makes reassembly easier. Use a block of wood between jack and suspension component to prevent damage.
   ⚠Do not over-lift with jack. Suspension should be at approximately ride height position only.
3. 3

   Disconnect electrical connections if equipped
   If the strut assembly includes electronic damping control or ride height sensors, locate and disconnect the electrical connector. Press the locking tab and carefully pull connector apart. Secure wiring out of the way with zip ties or tape to prevent damage during removal.
4. 4

   Remove lower strut mounting bolt
   Locate the lower strut mounting bolt that connects the strut to the rear knuckle or control arm. Use a wrench to hold the nut while loosening the bolt with a socket and breaker bar. The bolt may be seized due to corrosion. Remove the bolt completely and set aside. Note the orientation and any alignment shims or washers.
   ⚠Support the strut to prevent it from falling once lower bolt is removed.
5. 5

   Disconnect stabilizer bar link if necessary
   If the stabilizer bar link attaches to the strut assembly, remove the upper or lower link mounting nut (depending on configuration). Use two wrenches to prevent the ball joint stud from spinning. Once disconnected, move the link out of the way.
6. 6

   Remove upper strut mounting nuts
   From inside the cargo area, locate the upper strut mount nuts (typically 3 or 4 nuts around the strut shaft). Hold the strut shaft from spinning using the center hex or by having an assistant support the strut from below. Remove the upper mounting nuts completely. Mark the orientation of any alignment washers or eccentric bolts.
   ⚠️Strut may fall once upper nuts are removed. Ensure assistant is supporting strut or strut is secured with wire before removing final nut.
7. 7

   Remove strut assembly
   Carefully lower the jack supporting the suspension slightly to create clearance. Guide the strut assembly down and out of the strut tower while angling it through the suspension components. You may need to pivot or rotate the strut to clear brake lines, ABS sensors, or other components. Remove the strut from the vehicle.
8. 8

   Inspect and transfer components if necessary
   Inspect the mounting area for rust, damage, or debris. Clean the upper strut tower mounting surface with a wire brush. If reusing springs or upper mounts, use proper spring compressor to safely disassemble old strut and transfer components to new strut. If installing complete assembly, proceed to next step.
   ⚠️Spring compressor must be rated for vehicle weight and spring load. Improperly compressed springs can release with lethal force.
9. 9

   Install new strut assembly
   Apply anti-seize compound to upper mounting studs. Guide the new strut assembly up through the suspension, angling and rotating as needed to clear components. Align the upper mounting studs with the holes in the strut tower. Raise the jack under the suspension to help align lower mounting point.
10. 10

    Install upper mounting nuts
    From inside the cargo area, install the upper strut mounting nuts hand-tight. Ensure any alignment washers or spacers are in their original positions. Do not fully torque at this time. Install all nuts finger-tight first to ensure proper alignment.
11. 11

    Connect lower strut mounting
    Align the lower strut mounting hole with the knuckle or control arm. Install the lower mounting bolt and nut. Ensure any alignment shims or eccentric washers are in their original positions. Hand-tighten only at this stage.
12. 12

    Reconnect stabilizer link and electrical connections
    If previously disconnected, reconnect the stabilizer bar link to the strut or appropriate mounting point. Install the nut hand-tight. Reconnect any electrical connectors for electronic damping or sensors, ensuring the locking tab clicks into place.
13. 13

    Torque all fasteners to specification
    With vehicle at ride height (suspension loaded), torque all fasteners to Rivian specifications in the following sequence: upper strut mount nuts first, then lower strut bolt, then stabilizer link nut. CRITICAL: You must obtain proper torque specifications from Rivian service manual before performing this step. Do not proceed without verified torque values.
    ⚠️Under-torqued suspension fasteners can result in component separation and loss of vehicle control. Over-torquing can cause fastener failure. Use only verified Rivian torque specifications.
14. 14

    Repeat for opposite side
    Perform steps 2-13 for the opposite rear strut assembly. It is critical to replace both rear struts even if only one has failed to maintain balanced suspension performance and handling characteristics.
15. 15

    Reinstall wheels and lower vehicle
    Reinstall rear wheels and hand-tighten lug nuts in star pattern. Remove jack stands and carefully lower vehicle to ground. Torque wheel lug nuts to specification in star pattern (obtain specification from Rivian manual). Remove wheel chocks. Reconnect 12V battery.

Reassembly

1. Reinstall any interior trim panels or cargo area panels removed for access
2. Verify all electrical connections are secure and properly routed
3. Double-check that all fasteners have been properly torqued
4. Verify no tools or parts were left in wheel wells or cargo area

Verification

• Bounce each rear corner of vehicle and verify struts dampen movement properly without noise
• Test drive vehicle at low speed in safe area and verify handling feels normal with no clunking or unusual noises
• Inspect for any fluid leaks around new strut assemblies
• Verify electronic damping system functions properly if equipped (check for warning lights)
• CRITICAL: Schedule four-wheel alignment immediately. Vehicle should not be driven at highway speeds until alignment is verified
• After 50-100 miles, re-torque all suspension fasteners to specification and verify no loosening has occurred

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