This procedure covers the removal and replacement of the front upper control arm on a 2025 Rivian EDV 500 delivery van, including suspension disassembly and alignment considerations.

Warnings

Tools required

Parts

• Front upper control arm × 1 — Use OEM specification
• Upper ball joint nut × 1 — Use OEM specification
• Control arm mounting bolts/nuts × 2 — Use OEM specification
• Anti-seize compound × 1 — Copper or nickel-based

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
4. Loosen front wheel lug nuts while vehicle is on ground
5. Raise vehicle using floor jack at designated front lift points
6. Support vehicle on jack stands at frame rails, ensuring EDV-rated capacity
7. Remove front wheel on side being serviced
8. Spray all suspension fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Mark alignment reference points
   Before disassembly, use a paint pen or marker to mark the position of the upper control arm mounting bolts relative to the frame brackets. This will provide a rough reference for initial alignment setup and may reduce post-repair alignment time.
2. 2

   Support lower control arm
   Position a floor jack with a block of wood under the lower control arm, near the ball joint area. Raise jack slightly to take load off the upper control arm. This prevents the suspension from dropping excessively when the upper arm is disconnected and keeps components under control.
3. 3

   Disconnect wheel speed sensor and brake line
   Locate the wheel speed sensor connector near the upper control arm area and disconnect it. Carefully unclip any brake line or ABS sensor wire routing brackets attached to the upper control arm or knuckle in the work area. Do not disconnect brake hydraulics unless damaged; simply provide slack for knuckle movement.
4. 4

   Remove upper ball joint castle nut
   Remove the cotter pin (if equipped) from the upper ball joint castle nut. Using an appropriate socket, loosen and remove the castle nut from the ball joint stud. Keep the nut for reference even though it will be replaced, as it indicates proper thread engagement depth.
5. 5

   Separate upper ball joint from knuckle
   Insert a ball joint separator tool (pickle fork or proper puller) between the knuckle and the upper control arm ball joint. Strike or operate the tool to break the taper fit. If using a pickle fork, note that this may damage the ball joint boot. Once separated, support the knuckle assembly to prevent stress on the CV axle and lower ball joint.
6. 6

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the upper control arm to the frame bracket. This bolt typically runs horizontally through the control arm bushing. Using a breaker bar and socket, remove the bolt completely. Note the position and orientation of any washers, shims, or cam adjusters, as these affect alignment settings.
7. 7

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt securing the upper control arm to the frame bracket. Remove this bolt completely, again noting the position of any washers, shims, or eccentric cam adjusters. The control arm should now be free to remove from the vehicle.
8. 8

   Remove upper control arm
   Maneuver the upper control arm out of the mounting brackets and away from the vehicle. Inspect the frame mounting points for rust, damage, or elongated bolt holes. Clean the mounting surfaces with a wire brush and inspect bushings in the frame brackets for wear or damage.
9. 9

   Prepare new upper control arm
   Unpack the new upper control arm and verify it matches the original part in all dimensions and mounting hole positions. Check that the ball joint boot is intact and properly sealed. If the ball joint is serviceable, verify it moves smoothly without binding. Apply a thin coat of anti-seize compound to the ball joint stud threads.
10. 10

    Install new upper control arm to frame
    Position the new upper control arm into the frame brackets, aligning the bushings with the mounting holes. Install the front and rear mounting bolts finger-tight, transferring any alignment shims or cam adjusters from the original arm to match your reference marks. Do not fully torque at this time. Ensure bolts are inserted from the correct direction to match factory orientation.
11. 11

    Connect ball joint to knuckle
    Lower the knuckle assembly (or raise the control arm) to align the upper ball joint stud with the knuckle taper hole. Insert the stud fully into the knuckle. Install the new castle nut onto the ball joint stud and tighten by hand until seated, then continue tightening with a torque wrench. Since torque specs are not available in the database, tighten to a snug fit and ensure proper taper engagement. Install new cotter pin if equipped.
12. 12

    Torque control arm mounting bolts
    With the suspension loaded (jack supporting lower control arm), torque the front and rear upper control arm mounting bolts. Since specific torque values are not provided in the database, tighten bolts firmly using proper technique and verify no movement occurs in the bushings. These fasteners are critical suspension components and should be torqued to manufacturer specifications when available. Record that torque specs should be verified from Rivian service documentation.
13. 13

    Reconnect sensors and routing clips
    Reconnect the wheel speed sensor connector and secure all wiring and brake line routing clips to the control arm or nearby mounting points. Ensure no wires or lines are pinched, stretched, or at risk of contacting moving suspension components or the tire.
14. 14

    Reinstall wheel and lower vehicle
    Reinstall the front wheel and thread lug nuts by hand. Lower the vehicle from the jack stands until the tire contacts the ground but does not bear full weight. Torque lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands. Reconnect the 12V battery negative terminal.

Reassembly

1. Ensure all fasteners are properly torqued to manufacturer specifications once obtained from Rivian service documentation
2. Verify all electrical connectors are fully seated and secured
3. Check that brake lines and ABS wiring have proper clearance throughout suspension travel
4. Bounce the front suspension several times to settle components before final inspection

Verification

• Test 12V electrical systems to confirm battery reconnection was successful
• Verify wheel speed sensor functionality through vehicle diagnostics (no ABS warning lights)
• Check for any unusual noises when turning the steering wheel lock-to-lock
• Road test vehicle at low speed in a safe area, listening for clunks or unusual suspension noises
• Schedule professional four-wheel alignment immediately, as camber and caster settings have been disturbed
• After alignment, verify tire wear patterns are even and steering returns to center properly

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