Rivian Automotive is recalling 19,641 electric vehicles in the United States after identifying a potential safety issue linked to rear suspension components that may have been incorrectly reassembled during earlier service work, according to a filing with the U.S. National Highway Traffic Safety Administration (NHTSA).
The recall affects certain model-year 2022 to 2025 R1S sport utility vehicles and R1T pickup trucks that underwent service requiring the separation and reassembly of a rear suspension toe link joint. NHTSA said the issue stems from the use of an older service procedure applied between April 1, 2022, and March 10, 2025, before Rivian implemented an updated process. About 1% of the recalled vehicles are estimated to have the defect.
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According to the regulator, a toe link joint reassembled using the earlier procedure “may result in a joint that is not reassembled to design intent and could experience unintended forces.” In certain cases, continued vehicle motion could eventually lead to toe link separation, which “increases the risk of a crash without prior warning,” NHTSA said.
Rivian said it concluded an internal investigation in March 2025 after identifying a small number of reported toe link joint failures and subsequently revised its service procedures and training. “Since revision of the service procedures, no repair-related toe link failures have been reported,” the company said in the recall report.
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The automaker decided to initiate a voluntary safety recall on Dec. 26, 2025, after NHTSA notified the company of two customer complaints involving toe link failures tied to repairs carried out before the updated procedure was introduced. As of the filing date, Rivian said it was aware of one crash with alleged minor injuries linked to the issue.
As a remedy, Rivian will replace potentially affected rear toe link bolts using the updated service procedure, at no cost to owners. The company plans to mail owner notification letters by Feb. 24, 2026, when vehicle identification numbers will also become searchable in NHTSA’s recall database.
