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

Warnings

Tools required

Parts

• Front sway bar × 1 — Use OEM specification
• Sway bar frame bushings × 2 — Use OEM specification
• Sway bar end link assemblies × 2 — Use OEM specification
• Frame bushing bracket bolts × 4 — Use OEM specification
• End link nuts × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Turn vehicle power completely off and remove key fob from cabin
4. Lift vehicle using manufacturer-specified lift points until front wheels are off the ground
5. Support vehicle with appropriately rated jack stands as backup safety measure
6. Remove both front wheels and set aside
7. Spray all sway bar mounting hardware with penetrating oil and allow to soak for 10-15 minutes
8. Visually inspect the high-voltage system routing near the front suspension to identify components to avoid

Procedure

1. 1

   Document existing installation
   Take photos of the sway bar end link orientation, bushing positioning, and routing before disassembly. Note the direction of any offset bushings or specific clocking positions. Check for any spacers or shims present in the installation.
2. 2

   Disconnect passenger side end link
   Locate the sway bar end link connecting the sway bar to the passenger side lower control arm or strut assembly. Using a wrench to hold the end link stud, remove the upper and lower retaining nuts. Keep the washers and note their orientation. Separate the end link from both the sway bar and the control arm mounting point.
3. 3

   Disconnect driver side end link
   Repeat the end link removal process on the driver side. Hold the end link stud to prevent spinning while removing the nuts. Remove both upper and lower retaining nuts and separate the end link. Set aside all hardware in an organized manner.
4. 4

   Remove passenger side frame bushing bracket
   Locate the frame-mounted bushing bracket on the passenger side that secures the sway bar to the vehicle frame. Remove the two bracket mounting bolts using a socket wrench. The bracket may be secured with bolts that thread into captive nuts in the frame. Support the sway bar with one hand while removing the final bolt to prevent it from dropping.
5. 5

   Remove driver side frame bushing bracket
   Remove the driver side frame bushing bracket bolts in the same manner. Once both brackets are removed, carefully lower the sway bar from the vehicle. The bar may be heavy and awkward to maneuver around front suspension components and the front motor assembly. Rotate and angle the bar as needed to clear all obstructions.
6. 6

   Remove old bushings and inspect mounting points
   Remove the frame bushings from the sway bar by sliding them off or cutting them if they are degraded. Inspect the sway bar for cracks, deformation, or damage. Clean the mounting areas on the sway bar with a wire brush. Inspect the frame mounting surfaces and brackets for corrosion, cracks, or thread damage. Clean all mounting surfaces thoroughly.
7. 7

   Prepare new sway bar and install bushings
   If installing a new sway bar, verify it matches the original in length, diameter, and mounting point locations. Lubricate the new frame bushings with the supplied grease or a silicone-based lubricant (do not use petroleum-based lubricants on rubber bushings). Install the new bushings onto the sway bar in the correct orientation, ensuring the split in the bushing faces the correct direction per manufacturer specifications.
8. 8

   Install sway bar into position
   Carefully maneuver the sway bar into position, routing it through the front suspension area and around the front motor assembly. Align the bushing locations with the frame mounting brackets. You may need an assistant to support the bar while positioning it. Ensure adequate clearance from the motor housing, high-voltage cables, brake lines, and steering components.
9. 9

   Install driver side bushing bracket
   Position the driver side bushing bracket over the frame bushing, aligning the bracket holes with the frame mounting holes. Install the bracket bolts hand-tight initially. Ensure the bushing is seated properly in the bracket and not twisted or pinched. Do not fully torque at this time.
10. 10

    Install passenger side bushing bracket
    Install the passenger side bushing bracket in the same manner, ensuring proper bushing alignment and seating. Install bolts hand-tight. Verify the sway bar is centered and positioned correctly with equal clearance on both sides.
11. 11

    Connect end links
    Install the new or reused end links to connect the sway bar ends to the lower control arms or strut assemblies. Install the lower mounting first, then the upper mounting to the sway bar. Install washers in the correct orientation and thread nuts onto the studs hand-tight. Hold the stud with a wrench while tightening the nut to prevent stud rotation.
12. 12

    Torque all fasteners to specification
    Since no torque specifications are available in the database, consult the factory service manual or Rivian service information system for proper torque values. Torque the frame bushing bracket bolts first, then torque the end link nuts. Follow the manufacturer's torque sequence and specifications exactly. Typical sway bar hardware ranges from 40-80 ft-lbs but verify with official documentation before proceeding.

Reassembly

1. Reinstall both front wheels and torque lug nuts to manufacturer specification (consult service manual for exact value)
2. Lower vehicle carefully from jack stands and lift
3. With vehicle on the ground, bounce the front end several times to settle the suspension into its normal position
4. Perform a final inspection of all fasteners to ensure proper installation
5. Test drive vehicle at low speed in a safe area to verify proper handling and listen for any unusual noises

Verification

• Perform a visual inspection of all sway bar connections to ensure proper installation and clearances
• Verify no contact between the sway bar and any surrounding components including motor housing, suspension arms, and steering components
• Check that all fasteners are properly torqued and secured
• Turn the steering wheel full lock in both directions while stationary to ensure no binding or contact
• Test drive the vehicle and verify improved body roll control during cornering
• Listen for any clunking, rattling, or squeaking noises from the front suspension that might indicate improper installation
• After 50-100 miles of driving, re-inspect all fasteners and re-torque if necessary

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