FSAM 997 – Steering Knuckle and Control Arm May Separate – 2022 Rivian R1T, R1S, & EDV

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October 6, 2022 NHTSA CAMPAIGN NUMBER: 22V744000

Steering Knuckle and Control Arm May Separate

A loose steering knuckle fastener could separate, causing a loss of vehicle control and increasing the risk of a crash.

 

NHTSA Campaign Number: 22V744

Manufacturer Rivian Automotive, LLC

Components SUSPENSION, STEERING

Potential Number of Units Affected 12,212

 

Summary

Rivian Automotive, LLC (Rivian) is recalling certain 2022 R1T, R1S, and EDV vehicles. The fastener connecting the front upper control arm and steering knuckle may have been improperly tightened.

 

Remedy

Dealers will inspect and, as necessary, tighten the steering knuckle fastener, free of charge. Owner notification letters were mailed November 11, 2022. Owners may contact Rivian customer service at 1-888-748-4261. Rivian’s number for this recall is FSAM 997.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 


22V-744 Rivian Recall FSAM-997 SMS Notification

Important Recall Message from Rivian. Your 2022 Rivian is included in NHTSA Recall Number 22V-744. Rivian will offer no appointment necessary visits to Rivian Service Centers and pop-up locations 7 days a week as well as Mobile Service by appointment. By calling 855-RIVIAN5 (855-748-4265), 24/7-365, you can schedule an appointment and get information on Rivian Service Center and pop-up locations. Rivian Service Centers and pop-up service locations, with expanded hours of operation, are also listed on our website. https://rivian.com/support/article/where-can-i-take-my-rivian-to-get-the-upper-control-arm-fastener-inspected-and-f

 


RRC-18-22-001-1: Retorque Knuckle to Upper Control Arm Fasteners, R1T and R1S

Rivian has decided that a defect which relates to motor vehicle safety exists in certain model year 2022 Rivian R1T and R1S vehicles. Some of the population may have been built with improperly torqued fasteners between the knuckles and front upper control arms. An improperly torqued fastener could cause excessive wheel camber, or, in rare instances, a separation, affecting the driver’s ability to control the vehicle, and increasing the risk of a crash. Rivian will inspect and, as necessary, properly secure the knuckle fasteners in the affected vehicles. In the event that components require replacement, Rivian will replace components, as necessary.

Document Type Safety Recall Bulletin
Date October 7, 2022
Affected Region(s) USA
Affected Model(s) R1T, R1S
Model Year(s) 2022
Approximate Build Dates

Refer to the FSA Dashboard to determine if this document applies to a specific vehicle.

August 2021 – September 2022
Vehicle System 18 – Suspension
Minimum Service Location Service Center

 

Potentially Required Parts

Part Number Quantity Engineering Name Service Name/Notes
PT00001853-H 1 ASSY – UPR CONTROL ARM; FRT; LH Control Arm, Upper,

Front, LH

PT00001857-H 1 ASSY – UPR CONTROL ARM; FRT; RH Control Arm, Upper,

Front, RH

PT00001859-H 1 KNUCKLE_FR_LH Knuckle, Front, LH
PT00001860-H 1 KNUCKLE_FR_RH Knuckle, Front, RH

Attention: The parts listed in this table are only for unique steps that are called out in this bulletin.

Some sections of this bulletin might refer to Service Manual procedures which require additional parts. Always review the bulletin and all potentially related Service Manual procedures before ordering parts and beginning work.

 

Inspection

 Important: Perform this inspection on both the LH and RH sides of the vehicle. Do not continue to a different section until the inspection is complete on both sides.

  1. On the center display: Set the ride height to highest.

2.

  • When inspecting the LH side
  • When inspecting the RH side

3. Working in the rear of the wheelwell: Inspect the highlighted fastener.

 

Note: LH side shown.

a. If the fastener is loose, or can be freely spun by hand, perform the Replace Components section on the affected side.

b. Set a torque wrench to 20 Nm and attempt to tighten the fastener. If the fastener moves before 20 Nm is achieved, perform the Replace Components section on the affected side.

c. If the fastener is not loose and does not move before 20 Nm is applied, perform the Retorque Fastener section on the affected side.

Important: Each side of the vehicle might require a different action, based on the outcome of this inspection.

 

Replace Components

Important: Perform this section on either the LH side only, the RH side only, or both the LH and RH sides depending on the outcome of the Inspection section.

1. Replace: Knuckle, Front (refer to service manual procedure 181020010).

2. Replace: Control Arm, Upper, Front (refer to service manual procedure 181010010).

3. Reinstall all components that were removed for access and replace all non-reusable components. No additional work is required.

 

Retorque Fastener

Important: Perform this section on either the LH side only, the RH side only, or both the LH and RH sides depending on the outcome of the Inspection section.

  1. On the center display: Set the ride height to highest.

2.

  • When performing the steps in this section on the LH side
  • When performing the steps in this section on the RH side

3. Working in the rear of the wheelwell: Torque the highlighted fastener to 120 Nm.

 

CAUTION: When using a torque wrench with an offset socket, rotate the offset socket to exactly 90° from the body of the torque wrench. Other angles will cause an inaccurate torque measurement.

Note: If necessary: Use a wrench to hold the highlighted area while installing the fastener.

4. Loosen the nut 1/4 turn.

5. Repeat step 3 in this section.

6. On the center display: Set the ride height to standard.

 

Torque specifications in this section

Step Number Torque (Nm)
3 120

 


RRC-18-22-002-1: Retorque Knuckle to Upper Control Arm Fasteners, EDV

Rivian has decided that a defect which relates to motor vehicle safety exists in certain model year 2022 Rivian EDV vehicles, which, to date, have been delivered solely to Amazon. Some of the population may have been built with improperly torqued fasteners between the knuckles and front upper control arms. An improperly torqued knuckle fastener could cause excessive wheel camber, or, in rare instances, a separation, affecting the driver’s ability to control the vehicle, and increasing the risk of a crash. Rivian will inspect and, as necessary, properly secure the knuckle fasteners in the affected vehicles. In the event that components require replacement, Rivian will replace components, as necessary.

Document Type Safety Recall Bulletin
Date October 7, 2022
Affected Region(s) USA
Affected Model(s) EDV
Model Year(s) 2022
Approximate Build Dates

Refer to the FSA Dashboard to determine if this document applies to a specific vehicle.

December 2021 – September 2022
Vehicle System 18 – Suspension
Minimum Service Location Service Center

 

Potentially Required Parts

Part Number Quantity Engineering Name Service Name/Notes
PT00044840-D 1 ASSY – UPR CONTROL ARM; FRT; LH Control Arm, Upper,

Front, LH

PT00044838-D 1 ASSY – UPR CONTROL ARM; FRT; RH Control Arm, Upper,

Front, RH

PT00044843-E 1 KNUCKLE – FRT; LH Knuckle, Front, LH
PT00044842-E 1 KNUCKLE – FRT; RH Knuckle, Front, RH

 Attention: The parts listed in this table are only for unique steps that are called out in this bulletin.

Some sections of this bulletin might refer to Service Manual procedures which require additional parts. Always review the bulletin and all potentially related Service Manual procedures before ordering parts and beginning work.

 

Inspection

 Important: Perform this inspection on both the LH and RH sides of the vehicle. Do not continue to a different section until the inspection is complete on both sides.

1.

  • When inspecting the LH side
  • When inspecting the RH side

2. Working in the front of the wheelwell: Inspect the highlighted fastener.

 

Note: LH side shown.

a. If the fastener is loose, or can be freely spun by hand, perform the Replace Components section on the affected side.

b. Set a torque wrench to 20 Nm and attempt to tighten the fastener. If the fastener moves before 20 Nm is achieved, perform the Replace Components section on the affected side.

c. If the fastener is not loose and does not move before 20 Nm is applied, perform the Retorque Fastener section on the affected side.

Important: Each side of the vehicle might require a different action, based on the outcome of this inspection.

 

Replace Components

 Important: Perform this section on either the LH side only, the RH side only, or both the LH and RH sides depending on the outcome of the Inspection section.

1. Replace: Knuckle, Front (refer to service manual procedure 181020010).

2. Replace: Control Arm, Upper, Front (refer to service manual procedure 181010010).

3. Reinstall all components that were removed for access and replace all non-reusable components. No additional work is required.

 

Retorque Fastener

Important: Perform this section on either the LH side only, the RH side only, or both the LH and RH sides depending on the outcome of the Inspection section.

1.

  • When performing the steps in this section on the LH side
  • When performing the steps in this section on the RH side

2. Working in the front of the wheelwell: Torque the highlighted fastener to 120 Nm.

CAUTION: When using a torque wrench with an offset socket, rotate the offset socket to exactly 90° from the body of the torque wrench. Other angles will cause an inaccurate torque measurement.

Note: If necessary: Use a wrench to hold the highlighted area while installing the fastener.

3. Loosen the nut 1/4 turn.

4. Repeat step 2 in this section.

 

Torque specifications in this section

Step Number Torque (Nm)
2 120

 


Chronology :

On August 13, 2022, Rivian identified a vehicle where the upper control arm had separated from the steering knuckle. The incident was reviewed by engineering and an investigation into root cause and scope was
initiated.

On September 24, 2022, Rivian became aware of two vehicles where the steering knuckle had become loose or separated.

As of September 28, 2022, Rivian had become aware of six reports potentially related to this issue that had accumulated over the production of R1T, R1S, and EDV vehicles (a rate of 0.037%).

On September 29, 2022, Rivian completed its investigation, confirming the suspected root cause, risk assessment, remedy, and affected population.

On September 30, 2022, Rivian determined that a safety-related defect exists related to this matter.

 


3 Affected Products

Vehicles

MAKE MODEL YEAR
RIVIAN EDV 2022
RIVIAN R1S 2022
RIVIAN R1T 2022

 


12 Associated Documents

Recall Acknowledgement

RCAK-22V744-8353.pdf 645.627KB

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Defect Notice 573 Report

RCLRPT-22V744-5291.PDF 215.529KB

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Remedy Instructions and TSB

RCRIT-22V744-2408.pdf 824.456KB

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Remedy Instructions and TSB

RCRIT-22V744-7082.pdf 868.379KB

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Service Customer Email

RMISC-22V744-1988.pdf 123.562KB

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Email

RMISC-22V744-1881.pdf 136.926KB

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Recall 573 Report-Amendment 1 – 10/11/2022

RCLRPT-22V744-5844.PDF 215.716KB

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SMS Notification

RMISC-22V744-1054.pdf 46.346KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V744-8813.pdf 111.868KB

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Recall Quarterly Report #1, 2022-4

RCLQRT-22V744-4084.PDF 211.149KB

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Recall Quarterly Report #2, 2023-1

RCLQRT-22V744-3249.PDF 211.253KB

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Recall Quarterly Report #3, 2023-2

RCLQRT-22V744-0268.PDF 211.339KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V744&docType=RCL

 


 

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