Rivian faces pressure as 115,000 vehicle investigation puts rear suspension under scrutiny

This is not yet a recall of 115,000 vehicles

The NHTSA document says the agency opened preliminary evaluation PE26004, covering 2022 to 2025 model year R1S and R1T vehicles, a total of 114,922 units. A preliminary investigation can lead to a recall, but for now NHTSA is trying to establish whether the issue extends beyond a fault in Rivian’s earlier service procedure.

Two owner complaints triggered the investigation. In both cases, owners described the left rear toe link joint separating while driving, causing the vehicle to veer across multiple lanes. One incident ended in a collision with another vehicle and a roadside barrier. According to NHTSA, the two cases behind the investigation caused no injuries or deaths.

A small part that can change the car’s behaviour instantly

The rear suspension toe link is the control arm that holds the wheel’s directional angle. It determines how the rear wheel tracks relative to the vehicle’s longitudinal axis. If the arm or its mounting fails, the rear wheel loses its precise geometry and a heavy electric vehicle can suddenly begin to move sideways.

In Rivian’s case, the vehicle’s weight and performance make the problem more serious. The R1T and R1S are not ordinary electric cars. They are large four wheel drive adventure machines that carry a heavy battery, tow trailers and often work on poor surfaces. Rivian notes that the Gen 2 R1T can tow up to 3,493 kg or 4,990 kg, depending on battery and drivetrain, while the R1S can tow up to 3,493 kg. In that load class, the rear suspension must cope with vertical impacts as well as serious lateral forces.

Rivian already recalled 19,641 vehicles in January

There is already an earlier campaign in the background. According to NHTSA’s January recall 26V003, the issue affected 19,641 Rivians, specifically 7,031 R1S vehicles and 12,610 R1T vehicles. Those vehicles received service during which the rear toe link joint was separated and then reassembled using the old procedure. Rivian began using an updated method on 10 March 2025.

The recall description was blunt. A joint reassembled under the old procedure could receive unintended loads, the toe link could later separate while driving and the risk of a crash could increase without prior warning. Rivian decided on a voluntary recall on 26 December 2025 and said it would replace potentially affected toe link bolts free of charge under the updated procedure.

NHTSA now wants to know whether the problem ends with vehicles assembled incorrectly during service, or whether it reveals a wider sensitivity in the R1 platform’s rear suspension. The agency is examining the durability of the component under road conditions and service situations, comparing physical fracture evidence from the two incidents, assessing Rivian’s current repair procedure and checking the condition of toe links in vehicles already on the road.

Rivian disputes the suggestion of a design fault

According to Reuters, Rivian argues that its internal data shows the R1 toe link joint performs as designed. Rivian added that it is cooperating with NHTSA’s preliminary investigation, but said its own review does not show that the two owner complaints prove a design defect in the joint.

That distinction matters. If NHTSA sees a systemic design risk, the company could face a much larger recall. If the agency finds that the issue stems from an earlier service error or isolated incidents, the impact will be smaller. For now, this remains an investigation, not a confirmed recall of 114,922 vehicles.

For Europe, Rivian feels distant, but the lesson is close

The R1S and R1T are not officially on broad sale in Europe. Rivian’s own support page says reservations are currently limited to the US and Canada. So the investigation mainly concerns North American owners, not customers walking into European showrooms.

Even so, the story carries a clear message for Europe. Large electric SUVs and pick ups bring a new problem. The battery adds weight, the motors deliver torque instantly and off road modes make the suspension work in conditions that an ordinary premium SUV rarely sees. The Mercedes Benz G 580 with EQ technology, Range Rover Electric, Volvo EX90 and future electric commercial vehicles will all need to prove that their mechanical durability keeps pace with the brutal response of electric drivetrains.

The timing is bad for Rivian

Rivian needs confidence right now. The company built 42,284 vehicles in 2025 and delivered 42,247, but its growth story increasingly depends on the cheaper R2. In April 2026, Rivian said it had started production of saleable R2 vehicles and delivered the first cars to employees, with customer deliveries expected to follow soon.

That is why the rear suspension investigation hits the brand at a nervous moment. The R1T and R1S built Rivian’s reputation as strong, powerful, technological electric vehicles that genuinely belonged off road. If doubt lingers over the durability of their toe links or mountings, the effect does not stop with current owners. It also touches the credibility of the R2, because that smaller and cheaper model must lift Rivian from niche brand to larger manufacturer.

Technical summary

NHTSA preliminary evaluation PE26004 covers 114,922 Rivian R1S and R1T vehicles from model years 2022 to 2025.

The investigation centres on the rear suspension toe link, the control arm that keeps the rear wheel aligned.

Two owner complaints described the left rear toe link joint separating, with one case ending in a collision.

In January, Rivian recalled 19,641 vehicles because of a service procedure involving the same component.

A recall of 114,922 vehicles is not confirmed. NHTSA is still assessing the scope of the problem.