This procedure covers the removal and replacement of wheel studs on the 2025 Rivian EDV 500 dual motor AWD electric delivery van, including hub removal and stud pressing.

Warnings

Tools required

Parts

• Wheel studs × 5 — Use OEM specification
• Hub bearing assembly (if damaged) × 1 — Use OEM specification
• Axle nut (if damaged) × 1 — Use OEM specification
• Cotter pins × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind wheels that will remain on ground
3. Loosen lug nuts on affected wheel before raising vehicle
4. Consult service manual for designated jack points specific to EDV 500 model
5. Raise vehicle and support with appropriately rated jack stands at designated lift points
6. Remove wheel and tire assembly
7. Mark wheel orientation if reusing to maintain balance

Procedure

1. 1

   Remove brake caliper assembly
   Remove brake caliper mounting bolts and carefully remove caliper from bracket. Do not let caliper hang by brake hose. Use caliper hangers or wire to support caliper from suspension component. Do not disconnect brake line unless caliper replacement is required.
2. 2

   Remove brake rotor
   Remove rotor retaining screw if present. If rotor is seized to hub, use penetrating oil and light taps with dead blow hammer on rotor face to break corrosion bond. Mark rotor orientation if reusing to maintain balance with wheel assembly.
3. 3

   Remove axle nut and related components
   Remove cotter pin from axle nut if present. Use breaker bar and appropriate socket to remove axle nut. This nut will be under significant torque. Have assistant apply brakes or use wheel reattachment method to prevent hub rotation during removal. Keep axle nut for inspection; replace if damaged.
4. 4

   Disconnect suspension and steering components
   Remove lower control arm ball joint mounting hardware. Use ball joint separator to disconnect control arm from knuckle. If working on front axle, disconnect tie rod end from steering knuckle. Support knuckle assembly during removal to prevent CV joint damage.
5. 5

   Remove hub bearing assembly from knuckle
   Remove hub bearing mounting bolts from back of steering knuckle. Carefully extract hub assembly from knuckle. If hub is stuck, use appropriate puller to avoid damage. Do not strike hub directly with hammer as this can damage bearing races or ABS tone ring.
6. 6

   Inspect hub and bearing assembly
   Thoroughly inspect hub face for cracks, warping, or damage around stud holes. Examine bearing seals and races for wear or contamination. Check ABS tone ring for damage or missing teeth. If any damage is found beyond worn studs, replace entire hub bearing assembly. Clean hub face with wire brush.
7. 7

   Remove damaged wheel studs
   Using hydraulic press or wheel stud press tool, press out damaged or worn wheel studs from hub. Press from front (wheel side) toward back. Ensure hub is properly supported during pressing operation to prevent damage to bearing races. Mark stud positions if only replacing selected studs.
8. 8

   Clean stud mounting holes
   Clean all stud mounting holes in hub face with wire brush and solvent. Remove any corrosion, debris, or metal shavings. Inspect holes for damage, elongation, or cracks. Holes must be clean and undamaged for proper stud seating.
9. 9

   Press in new wheel studs
   Position new wheel stud into hole from back side of hub. Ensure stud is properly aligned and seated flush against hub face. Using hydraulic press or stud installation tool, press stud into hub until knurled section is fully seated and stud shoulder is flush with hub back face. Apply steady, even pressure. Verify stud is fully seated and not cocked in hole.
10. 10

    Verify stud installation
    Inspect each installed stud to ensure proper seating. Stud should not rotate in hub. Check that all studs protrude equal distance from hub face. Use dial indicator if available to verify stud perpendicularity and runout is within specification (typically less than 0.003 inches).
11. 11

    Reinstall hub bearing assembly
    Clean knuckle bore and hub mounting surface. Apply light coat of anti-seize to hub outer diameter (avoid ABS tone ring area). Install hub into knuckle, ensuring proper alignment with mounting holes. Install and hand-thread all hub mounting bolts before tightening. Due to lack of specified torque values in database, follow manufacturer service manual specifications exactly.
12. 12

    Reconnect suspension and steering components
    Reconnect lower control arm ball joint to knuckle. Install new cotter pins if applicable. If working on front axle, reconnect tie rod end to steering knuckle and install castle nut with new cotter pin. Ensure all suspension fasteners are tightened to manufacturer specifications.
13. 13

    Install axle nut and remaining components
    Install axle nut (use new nut if manufacturer requires). Torque axle nut to manufacturer specification while preventing hub rotation. Install new cotter pin if applicable and properly bend pins. Reinstall brake rotor in original orientation if reused, ensuring rotor sits flat on hub face.
14. 14

    Reinstall brake caliper
    Remove caliper from support hanger. Position caliper over rotor and align with mounting bracket. Apply thread locker to caliper mounting bolts per manufacturer specification. Install and torque caliper mounting bolts to specification. Pump brake pedal several times to restore pad contact before moving vehicle.
15. 15

    Install wheel and perform final checks
    Clean wheel mounting surface and stud threads with wire brush. Install wheel in original orientation if marked. Install lug nuts and hand-tighten in star pattern. Lower vehicle to ground while keeping weight supported. Torque lug nuts to manufacturer specification (typically 100-150 ft-lb for Rivian EDV) in star pattern sequence. Perform final torque check after initial test drive.

Reassembly

1. Ensure all suspension and steering fasteners are torqued to specification
2. Verify brake caliper is properly secured and brake pedal is firm before moving vehicle
3. Double-check lug nut torque after vehicle is lowered to ground
4. If front wheel studs were replaced, verify power steering operation and check for abnormal noises

Verification

• Test drive vehicle at low speed in safe area and verify no vibration or abnormal noises from affected wheel
• Check that wheel remains properly centered and no wobble is present
• Re-torque lug nuts after 50-100 miles of driving
• Verify ABS system operates correctly with no dashboard warning lights
• Inspect for any signs of looseness or movement in affected wheel assembly
• If front wheel was serviced, verify steering feel and alignment are normal; schedule alignment check if any concerns

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