2022 Rivian R1T

I am reporting repeated suspension and structural failures involving my 2022 Rivian R1T. In April 2026, at approximately 90,537 miles, Rivian performed a comprehensive inspection and found both front lower control arm bushings torn, the right rear damper leaking, and the rear subframe cracked. Rivian’s own service documentation specifically stated that the vehicle was “unsafe to operate due to damage to the rear subframe” and recommended that the vehicle be towed. Rivian subsequently replaced the rear subframe, both front lower control arms, the right rear damper, and serviced the hydraulic damper system. The April repair invoice totaled approximately $9,953. Approximately five months later, at approximately 96,956 miles, the vehicle developed another significant suspension problem. The front passenger side began sitting noticeably lower. The ride became extremely rough over bumps, I could feel significant vibration through the vehicle, and the vehicle repeatedly attempted to adjust its ride height. I also received warnings telling me not to move the vehicle while the air suspension was adjusting, and I was unable to properly adjust the ride height. I brought the vehicle back to Rivian in September 2026. The current Rivian service estimate calls for replacement of both front dampers, the air-suspension compressor/ASU, and the left and right front hydraulic suspension jounce lines, along with suspension diagnostics. The suspension repair estimate is approximately $7,121. I was informed that the ASU/compressor was tried as part of diagnosing the problem but did not resolve the condition, and the front dampers are now suspected. I was also informed that because the front suspension functions as a connected system and the replacement components are an updated design, both sides/components may need to be replaced. I am concerned about the repeated failure of safety-critical suspension and structural components on the same vehicle. In approximately five months .

We were driving on the highway going 70 MPH when we heard a loud bang, and then the car immediately catapulted to the right off the road and slammed into the concrete right median, spun around hit a sign and then ended up in the right bridge barrier (shoulder). During the crash 6 airbags deployed from the impact of the crash. The highway patrolman stated that you could see the driver-side rear wheel started skidding based on the marks on the road. We thought it was a blown tire. But the tires were all in tact. The driver-side rear wheel was turned out and it was clear that the toe-link joint had separated from the wheel axel and this is what caused our crash. The car has been totaled by insurance company and taken salvage yard in Knightdale, NC. We were both wearing seatbelts, and I (the passenger) was thrown around during the crash and ended up going to the hospital with neck and back pain. I have severe neck misalignment and soft tissue damage on my neck and back. I was unable to work for 4 days after the accident and still am not able to sleep well due to pain. We were in the right hand lane of the highway and did not hit any other cars, but if we had been in a different lane we could have hit another car and caused more injuries and damage. The problem that caused the accident was the problem that was listed on the product recall, we had an appointment to get it fixed the next day. We had the car towed to the Rivian service center where they verbally confirmed it was the toe link that separated. It was inspected by the police, the Rivian Service Center and our insurance adjuster. There was zero warning prior to the loud bang other than the recall notice We

Passenger front suspension failure due to failed hydraulic pump (at 67k miles), resulting in wheels rubbing against interior, making vehicle almost inoperable without placing occupants at risk. It was immediate and without warning inside vehicle. When I spoke with technician they informed me that it was occasionally reported in earlier models. I was unable to view component.

The 2022 R1Ts has a welded subframe that is prone to cracking due to the vehicles weight. The symptoms are a metal on metal clunking and creaking sound from the front end. In 2023 Rivian replaced the welded subframe on the R1T with a cast subframe that is stronger. I raised this issue to Rivian on 3 separate service appointments over the course of 3 years while my vehicle was under warranty, each time I was told that the sounds are normal. Now that my vehicle has just passed the 60,000 mile warranty period I am now being told that the truck needs the subframe replaced with the gen 2 retrofit kit at a cost of $11,500. As you can see by this Reddit thread, this is a systemic issue with the 2022 R1T and many customers have experienced cracks in the welded subframe- [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

2022 Rivian R1T, VIN [XXX] . On March 14, 2026, my service appointment at El Segundo Rivian service center [XXX] ) was deleted from the Rivian app along with all service requests and a timestamped customer message thread documenting my visit that day. Deleted items included active recall remedies FSAM-1795 (seat belt retractor bolts improperly torqued, NHTSA notification mailed ~March 9, 2026) and FSAM-1794 / NHTSA 26V003 (rear toe link improper reassembly, risk of joint separation while driving, notification mailed ~February 24, 2026), plus tire rotation, windshield replacement, and suspension repair. Both recalls were issued within 3 weeks of the deletion. This was the third of three consecutive failed appointments — all failed because El Segundo could not provide a promised loaner vehicle (January 21, February 10, March 14, 2026). The only surviving record [XXX] ) was altered by Rivian Service — they inserted the statement that ride height appears to be as expected and does not show variance before any inspection, directly contradicting my written report and a video I submitted through the Rivian app on January 2, 2026 at 9:34am documenting the defect. Rivian also added an all-caps requirement to replicate the issue on a test drive prior to intake despite existing written and video documentation. Rivian has a federal obligation to complete FSAM-1795 and FSAM-1794. Neither has been reinstated as of April 1, 2026. Formal complaint delivered to Rivian CEO via USPS Certified Mail March 18, 2026. Only response was a generic form letter (Inquiry #xxx) stating matter appears resolved. See also separately filed NHTSA complaint re suspension defect, same VIN. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

2022 Rivian R1T, VIN [XXX] . Recurring suspension defects since delivery June 2022, documented across 18 service visits over 3.5 years. Rivian performed multiple repairs including Gen 2 suspension component replacement. This defect has never been permanently resolved. On July 11, 2025, El Segundo service center [XXX] ) repaired the front end lowering in standard parking mode — causing the vehicle to sit unlevel and knock the tires out of alignment when driving off. They repaired the suspension and corrected the alignment. In August 2025 a related defect appeared: when exiting camp leveling mode, the vehicle does not return to drive height. Instead it behaves as though still entering camp mode, forcing a slow drive-away during which the vehicle behaves erratically, knocking tires out of alignment — the same mechanism as the July parking mode issue. I reported this to Rivian in fall 2025. Despite scheduling three appointments — January 21, February 10, and March 14, 2026 — El Segundo failed to complete service all three times due to inability to provide a promised loaner vehicle. Suspension unserviced since July 11, 2025 — 9 months. On March 31, 2026 I filmed the front end lowering in parking mode recurring — same defect supposedly repaired July 2025. Vehicle self-leveled when I manually raised the suspension, but recurrence after a Rivian repair attempt is a safety concern. Video dated March 31, 2026 available. Service appointment also deleted from Rivian app March 14, 2026 including active recall remedies FSAM-1795 and FSAM-1794 — addressed in separately filed NHTSA complaint. Surviving record altered by Rivian Service to state ride height appears normal before any inspection, contradicting my report and app video submitted January 2, 2026 at 9:34am. Formal complaint delivered to Rivian CEO via USPS Certified Mail March 18, 2026. No substantive response as of April 1, 2026. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Incident Overview: In late February 2026, at approximately 114,000 miles, this 2022 Rivian R1T suffered a comprehensive failure of its kinetic (hydraulic) suspension system. The failure occurred during normal on-road operation at approximately 60 mph in temperate (60°F) conditions. The vehicle has no history of off-road use or heavy hauling. Safety Risk & Critical Failure Mode: The suspension is a safety-critical system essential for vehicle stability, emergency braking, and predictable handling. A loss of hydraulic integrity in this system directly compromises the vehicle’s ability to maintain ride height and damping control. High-Speed Exposure: The initial failure manifested while traveling at 60 mph. Although a warning lamp was triggered, the vehicle’s functional safety logic failed to initiate a "limp mode" or restricted speed state. This allowed the 7,000lb vehicle to continue at highway speeds with a compromised high-pressure hydraulic circuit, posing an unreasonable risk of loss of control. Lack of System Redundancy: A localized hydraulic leak resulted in a cascading collapse of the entire architecture. Per the $10,662 service estimate, the repair requires replacing the front and rear dampers, hydraulic pump, manifold, and all fluid lines. This suggests a design-level vulnerability where a single-point failure in the hydraulic circuit necessitates a total system overhaul, indicating a lack of modularity or redundancy. Safety Protocol Gap: After diagnosing the leak, the authorized service center deferred to my personal judgment regarding operational safety. This forced an untrained consumer to make a critical safety determination on a high-pressure system while the vehicle remained capable of full highway speeds. Technical Confirmation: An authorized Rivian service center confirmed the failure on March 3, 2026, and determined a full system-wide replacement is required. All components are available for inspection. No prior warnings or symptoms were presen