From Alignment to Overhaul: How My Rivian R1T Ended Up With a Whole New Front End
You ever schedule something simple like an alignment and drive out with a brand-new front end? That’s how this story starts.
I booked a basic alignment for my 2025 Rivian R1T. When I arrived, Rivian added a Field Service Action for the half-shafts (FSAM-1717). No big deal, I figured it’d take a day. But once the work was done, the truck still pulled to the right. Even stranger, the steering wheel started sitting crooked when I changed ride heights.
A week later, I was back at Rivian Fife for a deeper inspection. The techs dug in and found the real issue: failed caster inserts inside the front subframe. Turns out, you can’t hold an alignment when your subframe geometry is off. The only fix? Replace the entire front subframe.
While they were in there, they also replaced both front hubs that had seized. Everything was covered under warranty, and I drove away with a brand-new front end and a perfectly straight steering wheel.
That’s when I started thinking about vehicle weight and overlanding setups. With the Max Pack battery, my R1T’s payload limit drops to around 1,500 pounds, and with all my gear, camper setup, and recovery equipment, I was likely close to the limit. Add my own weight and Miss Maple’s, and it’s easy to see how heavy these builds get.
Overloading your rig doesn’t just affect range, it stresses suspension components, subframes, and bearings. And while Rivian handled this one under warranty, they told me it wouldn’t be covered again if the vehicle was over gross weight in the future.
Now I’m rethinking my setup. Do I keep the Super Pacific camper or go lighter? Do I cut some gear or even lose a few pounds myself to balance things out? Either way, this was a wake-up call.
I’m still blown away by how Rivian handled everything. They didn’t just fix symptoms, they found the cause. But this whole experience taught me one big thing: know your weight, respect your limits, and maintain your rig before the trails teach you the hard way.
Got suggestions for how I should redesign the setup? Drop them in the comments below or message me on social. And stay tuned, the rebuild series starts soon.
