2022 Rivian R1T Suspension Problems

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)

Massive damper leak. Per research online, this is happening with a lot of the same vehicles. If it fails, it will place the vehicle in turtle mode even on the freeway which could be dangerous.

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

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)

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 (60F) 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

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.

Catastrophic failure of rear upper control arm / suspension resulting in temporary loss of control. Occurred driving straight at 35mph without any prior damage or symptoms.

Was driving through an intersection in traffic when I heard a loud explosion/metal-on-metal sound from the front drivers side of the vehicle. Instantly received two warnings in the IP; one for "Performance Limited" and the other for "Service Suspension Soon". The IP also stated speed was limited to 80MPH. I didn't notice any difference in driving but decided to pull over and check. Upon checking I identified a hydraulic suspension line completely disconnected and leaking hydraulic fluid in the front driver side wheel well. The wheel well also appeared to be covered in hydraulic fluid. Over the next 10-15 minutes the suspension became uneven/lopsided and the passenger side wheels were touching the wheel well. I called Rivian service and they said it was not safe to drive and had it towed to the Rivian service center. Rivian service is backlogged and will not be able to inspect and assess the damage until 9/21. Ultimately, I don't think the warnings accurately conveyed the severity of the issue and don't understand why the vehicle would let you drive up to 80mph when rivian service said it was not safe to drive.