NHTSA probes Rivian after suspension failures trigger loss of vehicle control
Two owners report sudden loss of control following fractures in critical suspension components, raising questions about repair protocols ahead of the R2 launch.
The US National Highway Traffic Safety Administration has opened a formal investigation into Rivian’s service procedures for rear suspension components on its R1 models. The probe follows two reports from owners who lost control of their vehicles after a bolt on the rear toe link fractured. Both affected vehicles had undergone previous servicing, with one incident occurring after the vehicle had been involved in a prior collision.
The regulator’s Office of Defects Investigation stated that Rivian first identified a sensitivity to service procedures regarding the rear toe link in March 2025. This discovery prompted the electric vehicle maker to update its handling and repair methods for the component. The current investigation will assess how the toe link responds to foreseeable road and service conditions, evaluate Rivian’s existing repair protocols, and examine the status of other 2023 and 2024 model year R1 vehicles.
According to the Office of Defects Investigation, nearly 115,000 vehicles could be affected by the issue. In January 2026, Rivian issued a recall for almost 20,000 vehicles, a move that included those that had received the toe link service prior to the March 2025 procedural improvements. The regulator noted that both complaints involved a sudden loss of control, with one driver swerving into another vehicle and colliding with a guardrail, while another owner described their R1S veering across lanes and onto a sidewalk.
Rivian has maintained that its internal data indicates the R1 toe link joints are operating as intended. The company also pointed out that one of the vehicles involved in the incidents was serviced by a third-party repair facility rather than a Rivian-owned centre. A spokesperson told TechCrunch that vehicle safety remains a top priority, though the specific details of the third-party involvement were not elaborated upon in the regulator’s initial statement.
The investigation coincides with a critical period for the manufacturer, as it prepares to begin deliveries of its R2 SUV in less than two weeks. Rivian has stated that the R2 features a simpler design intended to reduce mechanical complexity, thereby improving quality assurance and lowering servicing costs. To support its growing fleet, the company plans to expand its service network by adding over 50 new centres by the end of 2027, bringing the total to more than 150 locations, alongside an expansion of its mobile service van fleet.
