The U.S. National Highway Traffic Safety Administration (NHTSA) has opened an investigation into how Rivian services rear suspension components on its vehicles following reports from two owners who experienced a loss of vehicle control while driving.
The investigation is being conducted by the agency’s Office of Defects Investigation (ODI), which said both affected vehicles had previously undergone service work. One of the vehicles had also been involved in a collision before repairs were carried out.
Investigation Focuses on Rear Toe Link Component
According to the ODI, Rivian identified in March 2025 that the rear toe link—a key suspension component that helps maintain wheel alignment—showed a sensitivity to certain service procedures. Following that discovery, the company updated its repair and maintenance processes related to the component.
Federal investigators will now examine how and why the rear toe link may be vulnerable to foreseeable road and service conditions. The probe will compare the two reported incidents, review Rivian’s current repair procedures, and assess the condition of other affected vehicles.
The ODI said nearly 115,000 Rivian vehicles could potentially be included in the investigation.
Previous Recall Covered Nearly 20,000 Vehicles
The safety review follows a recall announced by Rivian in January 2026 covering nearly 20,000 vehicles. According to the ODI, the recall included vehicles that had received toe link service work before Rivian implemented its updated procedures in March 2025.
Rivian said it is cooperating with the investigation and emphasized that vehicle safety remains a top priority.
“Vehicle safety is a top priority at Rivian. Rivian data indicates R1 toe link joints are operating as intended.”
The company also noted that one of the vehicles involved in the complaints had been repaired by a third-party service facility.
Drivers Report Sudden Loss of Control
Both complaints submitted to the NHTSA involved a fractured bolt connected to the rear toe link assembly.
In one incident, the owner reported losing control of the vehicle at highway speeds, causing it to swerve into another vehicle before striking a guardrail head-on.
In the second complaint, the owner said the vehicle suddenly crossed multiple lanes of traffic after the left rear toe link failed.
“I was left with a sore neck for several days, my Apple Watch kept trying to call 911 thinking I was in an accident.”
The ODI said both incidents involved a sudden loss of steering stability after the toe link bolt fractured.
Investigation Comes Ahead of R2 Launch
The safety probe comes at a critical time for Rivian as the company prepares to begin deliveries of its new R2 electric SUV, which is expected to significantly increase sales volumes compared with the current R1T pickup and R1S SUV.
Rivian is also expanding its service infrastructure, with plans to add more than 50 new service centers by the end of 2027, bringing its network to more than 150 locations. The company is also increasing the size of its mobile service fleet.
The automaker has previously stated that the R2’s simplified engineering design should reduce maintenance requirements and improve serviceability.
“Reducing mechanical complexity during assembly results in higher quality assurance when vehicles roll off the line, simultaneously improving the ease and expense of servicing your vehicle if the need arises.”
The NHTSA investigation remains ongoing, and no determination regarding a safety defect has been announced.