Replacement of the upper control arm on a 2025 Rivian EDV 500 dual motor AWD electric delivery van, involving suspension disassembly and wheel alignment requirement.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification
• Upper control arm mounting bolts/nuts × 1 — Use OEM specification
• Upper ball joint castle nut (if separate) × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Verify high voltage system is in service mode or disabled per manufacturer service procedures
3. Loosen lug nuts on the wheel for the side being serviced while vehicle is on ground
4. Raise vehicle using appropriate lift points per owner's manual (avoid battery pack area)
5. Support vehicle on jack stands rated for at least 10,000 lbs
6. Remove wheel and tire assembly
7. Spray all suspension fasteners with penetrating oil and allow to soak for 15 minutes
8. Inspect surrounding area for high voltage cables and ensure they are secured away from work area

Procedure

1. 1

   Support lower suspension
   Position a floor jack under the lower control arm or knuckle assembly to support the weight of the suspension and prevent it from dropping when the upper control arm is disconnected. Raise jack just enough to slightly compress the suspension.
2. 2

   Disconnect wheel speed sensor (if equipped at upper area)
   Locate the wheel speed sensor wire routing near the upper control arm area. Disconnect any electrical connectors and carefully unclip or unbolt sensor wiring from the upper control arm to prevent damage during removal. Note routing for reinstallation.
3. 3

   Remove upper ball joint castle nut
   Locate the upper ball joint castle nut where the upper control arm connects to the steering knuckle. Remove the cotter pin and discard. Use a socket and breaker bar to remove the castle nut completely. Keep track of any washers or spacers.
4. 4

   Separate upper ball joint from knuckle
   Use a ball joint separator tool or pickle fork to separate the upper ball joint taper from the steering knuckle. Position the tool between the knuckle and control arm, then strike firmly or use the threaded separator mechanism. Be prepared for the knuckle to drop slightly once separated. Support the knuckle assembly with the floor jack to prevent strain on brake lines and CV axle.
5. 5

   Mark control arm mounting position
   Before removing the control arm mounting bolts, use a paint marker or scribe to mark the position of the control arm mounting brackets and any alignment cam bolts or eccentric bolts relative to the frame. This provides a baseline reference for initial alignment settings during reinstallation.
6. 6

   Remove front upper control arm mounting bolt
   Locate the front mounting bolt securing the upper control arm to the frame or subframe. This is typically accessed from above or through the wheel well. Use a socket and breaker bar to remove the bolt while supporting the control arm. Note the orientation and any washers or bushings.
7. 7

   Remove rear upper control arm mounting bolt
   Locate the rear mounting bolt securing the upper control arm to the frame or subframe. Remove this bolt using appropriate sockets while continuing to support the control arm. The control arm should now be free to remove from the vehicle.
8. 8

   Remove upper control arm
   Carefully maneuver the upper control arm out of the wheel well, paying attention to any nearby brake lines, ABS wiring, or high voltage cables. Inspect the mounting points on the frame for damage, corrosion, or wear. Clean mounting surfaces with a wire brush if necessary.
9. 9

   Prepare new upper control arm
   Unpack the new upper control arm and verify it matches the removed part. Check that all bushings are properly seated and that the ball joint boot is intact and properly lubricated. Transfer any reusable components if applicable (check service manual for specific guidance).
10. 10

    Install new upper control arm to frame
    Position the new upper control arm into the mounting location, aligning with the reference marks made during disassembly. Install the front and rear mounting bolts finger-tight only at this stage. Ensure any alignment cams or eccentric adjusters are positioned as close to the original marks as possible.
11. 11

    Connect ball joint to steering knuckle
    Use the floor jack to raise the knuckle assembly to meet the upper ball joint stud. Clean the ball joint taper and knuckle taper bore with a wire brush. Insert the ball joint stud into the knuckle, ensuring proper seating. Install the castle nut and tighten until snug.
12. 12

    Torque all fasteners
    With the suspension at normal ride height (supported by the floor jack), torque the upper control arm mounting bolts and ball joint castle nut to manufacturer specifications. Since torque specifications are not available in the database, consult the Rivian service manual for exact values. Install a new cotter pin through the castle nut and ball joint stud, bending ends to secure.
13. 13

    Reconnect sensors and wiring
    Reattach any wheel speed sensor wiring to the upper control arm using the original routing noted during disassembly. Ensure all clips and mounting points are secure and that wiring has adequate slack for suspension travel. Reconnect any electrical connectors.
14. 14

    Reinstall wheel and lower vehicle
    Install the wheel and tire assembly, threading lug nuts by hand. Lower the vehicle until the tire contacts the ground but vehicle weight is still on jack stands. Torque lug nuts to manufacturer specification in a star pattern. Remove jack stands and lower vehicle completely. Perform final lug nut torque check on the ground.

Reassembly

1. Ensure all fasteners are torqued to specification with suspension at ride height
2. Verify cotter pin is properly installed and secured through ball joint castle nut
3. Double-check that all electrical connections are secure and wiring is properly routed away from moving suspension components
4. Confirm high voltage systems are clear of the work area and any displaced cables are properly secured

Verification

• Perform visual inspection of all mounting points and fasteners to ensure nothing was missed
• Test drive vehicle at low speed in a safe area and listen for any abnormal suspension noises
• Check for proper steering response and verify no pulling to one side (though alignment will be off until professionally aligned)
• Schedule and complete professional wheel alignment immediately after repair - alignment is mandatory for safe operation and tire wear
• After alignment, verify steering wheel is centered and vehicle tracks straight
• Re-torque lug nuts after 50-100 miles of driving

More procedures for this vehicle