This procedure covers the removal and replacement of subframe bushings on a 2025 Rivian EDV 500 dual motor AWD electric delivery van, requiring subframe lowering and bushing press-out/press-in operations.

Warnings

Tools required

Parts

• Subframe bushing set (front and rear, typically 4-6 bushings) × 1 — Use OEM Rivian specification
• Subframe mounting hardware kit (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Disconnect 12V battery negative terminal and wait 5 minutes for system discharge
4. Enable high-voltage service mode per manufacturer procedure (consult service manual for EDV-specific lockout/tagout)
5. Raise vehicle on lift to comfortable working height with full suspension droop
6. Remove all four wheels and set aside
7. Spray all subframe mounting bolts and bushing bracket hardware with penetrating oil
8. Photograph or mark subframe position relative to body for reassembly reference

Procedure

1. 1

   Remove underbody protective panels
   Remove all underbody skid plates, battery protection panels, and aerodynamic covers that obstruct access to the subframe mounting points. The EDV 500 typically has extensive underbody protection. Label and store fasteners by location for reassembly.
2. 2

   Disconnect steering linkage and brake lines
   Disconnect the steering intermediate shaft at the steering rack pinion. Support brake hard lines and disconnect any brackets attaching brake lines to the subframe. Do not disconnect brake lines from calipers unless necessary. Support lines with wire or zip ties to prevent strain.
3. 3

   Disconnect control arms and stabilizer links
   Remove the fasteners connecting front lower control arms to the subframe. Remove stabilizer bar end links from the control arms or subframe mounting points. Allow suspension components to hang freely but support them to prevent damage to CV axles or other components.
4. 4

   Disconnect motor and drivetrain mounts
   Identify and disconnect the front electric motor mounts from the subframe. The dual motor AWD configuration will have front motor mounts attached to this subframe. Use a transmission jack or engine support to bear the weight of the motor assembly before removing mount fasteners. Mark orientation of any shim plates.
5. 5

   Disconnect electrical harnesses and coolant lines
   Carefully detach any electrical harnesses clipped or routed along the subframe. Disconnect motor coolant lines if they pass through or attach to subframe mounting points. Have drain pan ready if coolant lines must be opened. Cap any open coolant fittings immediately.
6. 6

   Support subframe with hydraulic jack
   Position hydraulic transmission jack or dedicated subframe support fixture under the center of the subframe. Raise jack until it just contacts the subframe and bears a small amount of weight. Use a large wood block or subframe adapter to distribute load evenly. Ensure jack is stable and centered.
7. 7

   Mark subframe alignment position
   Using a paint marker, scribe alignment marks between the subframe mounting flanges and the body mounting points on all four corners. These marks are critical for proper reassembly and maintaining suspension geometry. Take additional measurements if bushings have allowed significant movement.
8. 8

   Remove subframe mounting bolts
   Working systematically, loosen all subframe-to-body mounting bolts approximately 2-3 turns each to relieve tension evenly. Then remove bolts completely, starting with the rear bolts first. Keep bolts organized by location. The subframe weight should now be fully supported by the hydraulic jack.
   ⚠️Ensure jack is stable and subframe cannot shift or fall during bolt removal.
9. 9

   Lower subframe for bushing access
   Slowly and carefully lower the hydraulic jack to drop the subframe approximately 6-8 inches or until bushings are fully accessible. You may not need to completely remove the subframe depending on bushing location. Verify all connections are clear and nothing is binding as subframe lowers.
10. 10

    Remove old bushings
    Using a bushing press tool or hydraulic press with appropriate adapters, press out the old subframe bushings from their mounting locations. Work carefully to avoid damaging the subframe bushing bores. If bushings are extremely seized, carefully cut the outer shell with a reciprocating saw, taking care not to damage the bore.
11. 11

    Clean and inspect bushing bores
    Thoroughly clean all bushing mounting bores with wire brush and solvent. Remove all rust, debris, and old bushing material. Inspect bores for cracks, elongation, or damage. Check subframe for any cracks or stress damage around bushing locations. Any structural damage requires subframe replacement.
12. 12

    Install new bushings
    Apply bushing installation lubricant (polyurethane grease) to the outer surface of new bushings and inner bore surfaces. Align bushing orientation per manufacturer instructions (bushings may be directional). Using bushing press tool or hydraulic press with proper adapters, press new bushings squarely into bores until fully seated and flush with mounting surface.
13. 13

    Raise and align subframe
    Carefully raise the hydraulic jack to lift the subframe back into position. Use the alignment marks made during disassembly to position the subframe correctly. You may need an assistant to guide the subframe into position while you operate the jack. Align all mounting bolt holes with body mounting points.
14. 14

    Install subframe mounting bolts
    Install all subframe mounting bolts finger-tight first to ensure proper alignment. Once all bolts are started, tighten them in a cross-pattern sequence to ensure even loading. Note: Torque specifications are not available in the database - consult Rivian service manual for exact torque values. Typically subframe bolts require 150-200 ft-lb and should be torqued in stages.
15. 15

    Reconnect all components
    Reconnect the front motor mounts, control arms, stabilizer links, steering linkage, brake line brackets, electrical harnesses, and coolant lines in reverse order of removal. Ensure all fasteners are torqued to specification per service manual. Verify coolant line connections are secure and not leaking.

Reassembly

1. Reinstall all underbody protective panels and skid plates with original fasteners
2. Reinstall wheels and torque lug nuts to specification (typically 150 ft-lb for commercial vehicles, verify in service manual)
3. Refill EV motor/battery coolant system to proper level if lines were opened, then bleed air from system
4. Reconnect 12V battery negative terminal
5. Disable high-voltage service mode and restore vehicle to normal operation mode
6. Lower vehicle to ground

Verification

• Start vehicle and verify no warning lights or error codes related to drivetrain or suspension systems
• Check for any coolant leaks around motor or battery cooling system connections
• Perform steering lock-to-lock test while stationary to verify full range of motion without binding
• Test drive vehicle at low speed in safe area, listening for any unusual noises from subframe area
• Verify steering feels centered and vehicle tracks straight with no pulling
• Schedule wheel alignment at qualified facility with EV experience within 50 miles of repair
• Re-torque subframe mounting bolts after 100-200 miles of driving as bushings may settle

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