Rivian has issued a new recall covering nearly 20,000 R1T and R1S vehicles in the United States, after identifying a potential issue tied not to vehicle production, but to how certain suspension components were reassembled during prior service visits.
According to a filing with the National Highway Traffic Safety Administration (NHTSA), the recall affects 19,641 vehicles from the 2022–2025 model years that previously underwent service work involving the rear suspension toe link. In some cases, Rivian says the joint may not have been reassembled to its intended design specification when serviced using an older procedure in place before March 10, 2025.
The toe link is a critical suspension component that helps control wheel alignment. If the joint was improperly reassembled, Rivian warns that normal vehicle motion over time could introduce unintended forces, potentially leading to separation of the joint while driving. NHTSA notes that such a failure could occur without warning and increase the risk of a crash.
Rivian is aware of one crash with alleged minor injuries potentially linked to the issue.
The recall is limited to vehicles that received this specific type of service during the defined suspect period. Rivian determined the affected population by reviewing internal service records, excluding vehicles that never required toe link separation or that were serviced after the updated procedure was introduced.
Rivian traced the issue back to a small number of reported toe link joint failures, concluding its internal investigation in March 2025. Since revising its service procedures and training, the company says no additional repair-related toe link failures have been reported. However, after NHTSA notified Rivian of two recent customer complaints in mid-December, the company moved forward with a broader recall.
The fix is straightforward but will of course require a service visit. Rivian will replace the rear toe link bolts free of charge using the updated service procedure.
You can read the full recall notice below. Transport Canada has yet to issue a similar recall.
