This procedure covers the removal and replacement of the front sway bar bushings on a 2025 Rivian EDV 500 electric delivery van with dual motor AWD configuration.

Warnings

Tools required

Parts

• Front sway bar bushing set (left and right) × 1 — Use OEM specification
• Sway bar bushing bracket bolts (if corroded) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Access vehicle settings through center display and enable Service Mode to lock air suspension at current height
4. Allow suspension and steering components to cool if vehicle was recently driven
5. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
6. Apply penetrating oil to sway bar bushing bracket bolts and allow to soak for 10-15 minutes
7. Verify lift points according to Rivian service manual - front lift points are located on reinforced frame rails behind front wheels

Procedure

1. 1

   Lift and secure vehicle
   Raise vehicle using proper lift points on the front frame rails. Lift vehicle to working height and support with jack stands rated for electric vehicle weight. Remove front wheels and set aside. Verify vehicle is stable before working underneath.
2. 2

   Remove underbody protection (if equipped)
   If vehicle is equipped with front underbody skid plates or protective panels, remove fasteners securing panels that obstruct access to front sway bar area. Some EDV models have plastic undertray panels secured with push clips and bolts. Set panels and hardware aside in organized manner for reinstallation.
3. 3

   Inspect sway bar and bushing condition
   Visually inspect the front sway bar for damage, cracks, or deformation. Check sway bar end links for wear or damage. Examine existing bushings for deterioration, cracking, or oil contamination. Note the orientation of bushing splits (typically facing forward or rearward) for proper reinstallation. Take photos if needed for reference.
4. 4

   Support sway bar with jack
   Position hydraulic floor jack under center of front sway bar with wood block or rubber pad to protect bar surface. Apply slight upward pressure to relieve tension on bushing brackets. Do not lift sway bar significantly, only enough to unload bushing clamps.
5. 5

   Remove driver side bushing bracket
   Locate the driver side (left) sway bar bushing bracket bolted to the front subframe or crossmember. Remove the two bracket retaining bolts using appropriate socket. If bolts are seized, apply additional penetrating oil and allow to soak. Remove bracket and extract worn bushing from around sway bar. Note bushing orientation and any alignment marks on bracket.
6. 6

   Remove passenger side bushing bracket
   Repeat removal process for passenger side (right) sway bar bushing bracket. Remove the two bracket bolts and extract bracket with worn bushing. Keep left and right hardware separate if brackets are side-specific. Inspect bracket mounting surfaces on subframe for corrosion or damage.
7. 7

   Clean sway bar and mounting surfaces
   Use wire brush to clean sway bar surface where bushings mount, removing old rubber residue, corrosion, and debris. Clean bracket mounting surfaces on subframe. Inspect sway bar for scoring or damage that could cause premature bushing failure. Clean inside of bushing brackets if reusing.
8. 8

   Prepare and install new bushings
   Apply thin layer of polyurethane bushing grease or silicone lubricant to inside diameter of new bushings and contact area of sway bar. Do not use petroleum-based lubricants as they degrade rubber. Open split in bushing and position around sway bar in correct orientation with split facing as noted during removal (typically forward or rearward depending on design). Ensure bushing is centered on bar between bracket mounting points.
9. 9

   Install driver side bushing bracket
   Position bracket over bushing, ensuring bushing remains centered and properly oriented. Align bracket with mounting holes in subframe. Start both bracket bolts by hand to ensure proper thread engagement. Using appropriate socket and ratchet, tighten bolts in alternating pattern to compress bushing evenly. Since specific torque values are not available in database, follow manufacturer specifications from service manual or tighten to snug specification typical for suspension bracket bolts (approximately 35-50 ft-lbs, verify with OEM documentation).
10. 10

    Install passenger side bushing bracket
    Repeat installation process for passenger side bushing bracket. Ensure bushing is centered and oriented correctly before positioning bracket. Start both bolts by hand, then tighten in alternating pattern. Apply same torque specification as driver side bracket. Verify bushing is not twisted or pinched by bracket.
11. 11

    Remove support jack and verify installation
    Carefully lower and remove hydraulic jack from under sway bar. Visually inspect both bushing installations to ensure brackets are fully seated, bushings are centered, and no gaps exist between bracket and mounting surface. Check that sway bar moves freely within bushings without binding. Verify end links remain properly connected.
12. 12

    Reinstall underbody protection
    If underbody panels or skid plates were removed, reinstall them in reverse order of removal. Ensure all fasteners, push clips, and bolts are properly secured. Verify no tools or parts were left in underbody area.
13. 13

    Reinstall wheels and lower vehicle
    Reinstall front wheels and hand-tighten lug nuts in star pattern. Lower vehicle from jack stands and remove stands. Lower lift until wheels just contact ground with weight still supported. Torque lug nuts to manufacturer specification (typically 140-150 ft-lbs for Rivian EDV, verify with OEM documentation) in star pattern. Fully lower vehicle to ground.

Reassembly

1. Disable Service Mode through vehicle center display to restore normal air suspension operation
2. Remove wheel chocks from rear wheels
3. Verify all tools and parts have been removed from work area and vehicle undercarriage
4. Dispose of old bushings according to local regulations

Verification

• Start vehicle and verify no warning lights or suspension fault messages appear on instrument cluster
• Perform visual inspection under vehicle to confirm all brackets are secure and no interference exists between components
• Test drive vehicle at low speed in safe area and verify steering returns to center properly
• Drive over small bumps and through moderate turns to verify no clunking, rattling, or unusual noises from front suspension
• Check for excessive body roll during cornering compared to pre-repair condition
• After 50-100 miles of driving, re-inspect bushing bracket bolt tightness and verify bushings have not shifted position
• Monitor for any changes in vehicle handling or suspension noise during initial break-in period

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