From Alignment to Overhaul: How My Rivian R1T Ended Up With a Whole New Front End

[starbux]

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, but that word was not correct for them to use. When they try and rotate the hub and if it does not freely spin, they tend to replace them now. 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?

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[mkhuffman]

Too bad about the weight limit, because your build looks awesome.

 

[Rade]

Warranty work is always nice!

 

[GeorgeHudetz]

Thanks for the write-up and the thoughts on weight. I'm in the process of deciding which way to go on my R1T myself.

I've been thinking that if I don't get a camper, I'd get a RTT, a set of crossbars, a tonneau cover, and some kind of sliding bed arrangement. Not sure I could make all that work with access to the spare as I have not looked into the details, but I do wonder how close the weight of all that compares to a lightweight camper.

 

[starbux]

Too bad about the weight limit, because your build looks awesome.

I am working today on emptying the entire truck and going to weigh it with the gear tunnel slider and the tent still on. Go from there to see if it is even possible.

 

[starbux]

Thanks for the write-up and the thoughts on weight. I'm in the process of deciding which way to go on my R1T myself.

I've been thinking that if I don't get a camper, I'd get a RTT, a set of crossbars, a tonneau cover, and some kind of sliding bed arrangement. Not sure I could make all that work with access to the spare as I have not looked into the details, but I do wonder how close the weight of all that compares to a lightweight camper.

I had an iKamper for a while and loved it. Was able to take it off when I needed the bed and put it back on when I was ready to camp.

 

[Just Passing By]

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.

Super Pacific spec the T1 camper at 342 lbs. The 1500 lbs payload is in line with those of other mid-size ICE trucks, some are higher, others similar or lower for the off-road spec versions, pretty much all have been fitted with Super Pacific or other wedge campers with similar or heavier spec'd weight (looking at you Alu-Cab). Certainly some of those ICE vehicles are going to be overweight. However no reason in your case why being a bit careful about what gets loaded shouldn't still leave plenty of spare payload.

 

[boosted20v]

had the exact same thing happen. Scheduled an alignment after swapping wheels and tires. They ended up replacing everything but the struts!

 

[sacramentoelectric]

That wind deflector really improves the look of the Super Pacific. Part of the reason I went with the GFC was how high the SP was over the roof fin but the deflector helps balance out the look. I saw in one of your earlier videos that it's loud. I'm surprised the deflector increased your wind noise. You're really seeing 1.5 m/kwh over 65? I never hit 2 but I'm more like 1.8 on my all-terrains + GFC at about 70.

 

[mmbmca]

I'mna share this with thread with Rivian hope they replace the sub frame this time. Vehicle is going in 6th time for alignment in 14 months of ownership

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