Torsion Bar

This procedure covers the removal and replacement of the front or rear torsion bar on the 2025 Rivian EDV 500 electric delivery van, including safe unloading of suspension tension and proper reinstallation.

Warnings

Tools required

Parts

• Torsion bar (specify front or rear) × 1 — Use OEM specification
• Torsion bar adjustment bolt kit (if damaged) × 1 — Use OEM specification
• Torsion bar mounting hardware kit × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind wheels opposite to side being serviced
3. Disconnect 12V battery negative terminal and wait 2 minutes
4. Enable high-voltage service mode through vehicle service menu or Rivian service tool
5. Verify HV system is disabled by checking service mode indicator
6. Measure and record current ride height at all four corners for reference
7. Spray all torsion bar mounting hardware with penetrating oil and allow 15 minutes to soak
8. Raise vehicle and support on manufacturer-approved jack stand locations
9. Remove wheel and tire on side being serviced

Procedure

1. 1

   Mark torsion bar adjustment position
   Before making any adjustments, use paint pen or marking tool to mark the current position of the torsion bar adjustment bolt relative to the adjustment arm. Count and record the number of threads visible on the adjustment bolt. Take photos for reference. This will help restore approximate ride height during reassembly.
2. 2

   Support lower control arm
   Position a floor jack under the lower control arm near the ball joint. Raise jack just enough to take slight load off the suspension, but do not lift the vehicle. This provides stability during torsion bar unloading and prevents sudden movement.
3. 3

   Install torsion bar unloading tool
   Install the Rivian torsion bar unloading tool onto the adjustment bolt and torsion bar anchor. Follow tool manufacturer instructions for proper engagement. Ensure tool is securely seated and aligned before applying force. The tool will allow controlled release of torsion bar tension.
4. 4

   Unload torsion bar tension
   Using the unloading tool, slowly and carefully increase tension on the tool to slightly load the adjustment bolt, then remove the adjustment bolt lock nut. Continue using the unloading tool to slowly release tension from the torsion bar in small increments. Monitor the suspension for movement. Completely unload all tension from the torsion bar adjustment. This may take several minutes of gradual release.
5. 5

   Remove torsion bar adjustment components
   Once tension is fully released, remove the adjustment bolt completely. Remove the adjustment arm from the torsion bar anchor point. Mark the orientation of the adjustment arm relative to the vehicle for correct reassembly. Remove any retaining clips or hardware securing the adjustment mechanism.
6. 6

   Mark torsion bar orientation
   Before removing the torsion bar, mark its orientation relative to the mounting points. The torsion bar has specific front and rear ends with indexed splines. Use paint pen to mark the bar and corresponding mounts. Note: Front and rear torsion bars are NOT interchangeable.
7. 7

   Remove rear torsion bar mount
   Remove the bolts securing the rear torsion bar anchor bracket to the frame. The anchor bracket may be seized due to the torsion bar tension over time. Carefully work the bracket free, using a pry bar if necessary. Do not damage the frame mounting surface.
8. 8

   Remove torsion bar from front mount
   At the front control arm location, remove the hardware securing the torsion bar to the lower control arm. Note the orientation and position of any spacers or alignment shims. The torsion bar may require some manipulation to slide out of the control arm socket due to spline engagement.
9. 9

   Extract torsion bar
   Carefully slide the torsion bar rearward and out of the vehicle. The bar is heavy and awkward to handle. Support the bar to prevent it from falling or striking other components. Inspect the removed bar for damage, scoring, or corrosion. Check all mounting points and splines for wear.
10. 10

    Prepare mounting points
    Clean all torsion bar mounting splines and sockets with wire brush. Remove any corrosion, debris, or old anti-seize compound. Inspect all mounting hardware for damage or excessive wear. Replace any worn or damaged components. Apply light coat of anti-seize compound to splines (do not over-apply as excess can attract debris).
11. 11

    Install new torsion bar
    Align the new torsion bar with the front control arm mount, matching the orientation marks from disassembly. Slide the front end of the torsion bar into the control arm socket, ensuring splines are properly engaged. The bar should seat fully without excessive force. If resistance is encountered, verify correct alignment and spline engagement.
12. 12

    Install rear anchor bracket
    Position the rear anchor bracket onto the torsion bar rear splines, aligning with frame mounting holes. Install mounting bolts finger-tight. Verify proper alignment before final tightening. The bracket must be correctly indexed on the torsion bar splines per alignment marks.
13. 13

    Secure all mounting hardware
    Tighten all torsion bar mounting hardware to specification. Since no torque specifications are provided in the database, follow Rivian service manual torque values. Tighten frame-to-bracket bolts first, then control arm mounting hardware. Verify all fasteners are properly seated and torqued.
14. 14

    Install adjustment arm and load torsion bar
    Install the adjustment arm onto the rear anchor in the marked orientation. Thread the adjustment bolt into position to match the pre-service marks and thread count. Use the unloading tool to gradually apply tension to the torsion bar by tightening the adjustment bolt. Bring the adjustment to approximately the same position as recorded during disassembly. Install and tighten the adjustment bolt lock nut.
15. 15

    Verify installation and prepare for alignment
    Remove the torsion bar unloading tool. Lower the floor jack from under the control arm slowly while monitoring suspension movement. Reinstall wheel and tire, torque lug nuts to specification. Lower vehicle to ground. Measure ride height and compare to pre-service measurements. Minor adjustments can be made, but full alignment must be performed at a qualified facility.

Reassembly

1. Ensure all mounting hardware is torqued to specification per Rivian service manual
2. Verify torsion bar adjustment bolt lock nut is properly tightened
3. Check that no tools or parts were left in the suspension area
4. Reinstall any underbody panels or protective covers removed during service
5. Reconnect 12V battery and exit high-voltage service mode following Rivian procedures

Verification

• Verify ride height is within 10mm of pre-service measurement on the serviced side
• Bounce suspension several times to settle components and recheck ride height
• Inspect all torsion bar mounting points for proper seating and security
• Test drive vehicle at low speed in safe area to verify normal suspension operation and absence of unusual noises
• Schedule four-wheel alignment within 24 hours of torsion bar replacement
• After alignment, recheck all mounting hardware torque specifications

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