NHTSA Investigates Rivian Rear Suspension Failures Affecting Up to 115,000 R1 Vehicles

The National Highway Traffic Safety Administration's Office of Defects Investigation has opened a formal probe into Rivian's rear suspension service procedures following two reported incidents where drivers lost control of their vehicles due to rear toe link failures. Both complaints involved previously serviced R1 model vehicles, with one having been in a collision prior to service work. The investigation will examine why the rear toe link—a critical suspension component responsible for keeping wheels properly aligned—is sensitive to service and road conditions, and could potentially affect nearly 115,000 vehicles from the 2023-2024 model years.

Rivian identified the issue with its rear toe link service procedures in March 2025 and subsequently updated its handling protocols. The company issued a recall in January 2026 for approximately 20,000 vehicles that had received toe link service before the March 2025 improvements were implemented. According to owner complaints, the failures occurred when bolts on the toe link fractured suddenly, causing abrupt loss of vehicle control. In one incident, a driver swerved into another vehicle and collided head-on with a guardrail at highway speeds. In the second case, an R1S owner reported their vehicle veering across multiple lanes, onto a bike path and sidewalk before returning to the roadway.

Rivian has stated that vehicle safety is a top priority and maintains that its R1 toe link joints are operating as intended, noting that one of the affected vehicles was serviced by a third-party repair facility rather than an authorized Rivian service center. The investigation will evaluate Rivian's current toe link repair procedures and assess the condition of other affected R1 vehicles. The timing of this investigation comes as Rivian approaches the launch of its R2 SUV, expected to begin deliveries within two weeks, which the company anticipates will achieve significantly higher sales volumes than its current lineup.