by Federal investigation into Rivian suspension issues
The National Highway Traffic Safety Administration (NHTSA) has launched a new investigation into 114,922 Rivian R1S and R1T vehicles. The reason is reports that rear toe links can detach while driving, causing sudden and dangerous maneuvers.
Two owners of 2023 and 2024 Rivian R1S vehicles encountered detachment of the left rear toe link. In both cases, the vehicles sharply changed lanes after the failure. One accident resulted in a collision with another vehicle and a road barrier.
Investigators determined that it was not the links themselves that broke, but the bolts that secure them. Evidence includes repair records, onboard camera footage, photographs, and a police accident report.
Different histories, same problem
Interestingly, the two affected vehicles had different histories. One had previously undergone service maintenance, the other had been in an accident. Despite this, both SUVs drove thousands of kilometers without issues before the links suddenly failed.
Rivian has already faced this problem. The company was aware of rear suspension defects, specifically that improperly assembled connections could experience excessive loads and disconnect over time.
Incorrect fix
Rivian acknowledged the connection’s sensitivity to maintenance procedures and updated its repair instructions in March 2025. In early 2026, the company recalled nearly 20,000 R1T and R1S vehicles after it was discovered that service technicians had been using outdated procedures since 2022.
Now federal regulators want to determine whether the problem extends beyond improper repairs. A new preliminary evaluation will examine how vulnerable the toe link assembly is in real-world road conditions. Investigators are also comparing damaged parts from both incidents for commonalities.
Rivian
For now, Rivian drivers should be prepared for the possibility that the rear suspension could test their reactions at the most unexpected moment. The situation is complicated by the fact that even after updated instructions and a recall, the problem may be deeper than just service center errors. This underscores the importance not only of proper repairs but also of the structural reliability of components responsible for vehicle safety. The ongoing NHTSA investigation could lead to a broader recall or even demands for suspension design changes, which would pose a serious challenge for the electric vehicle manufacturer.
