Rivian is recalling nearly 20,000 R1 vehicles in the United States due to an incorrectly assembled rear toe link during service repairs, the US National Highway Traffic Safety Administration said on Thursday.
The recall affects vehicles produced from 2022 to 2025, that have been reassembled by service teams before March 2025.
According to NHTSA, the toe joint link, a component of the vehicle’s suspension, may separate, increasing the risk of a crash.
In the recall notice, submitted on Monday, Rivian said it will replace the rear toe-link bolts free of charge, expecting owners to be notified by February 24, 2026.
According to the company, an investigation was conducted in March 2025 regarding reported toe link joint failures after interventions by service teams.
Following two recent complaints with the NHTSA in mid-December, the company “decided to conduct a voluntary safety recall of all potentially affected vehicles with subject repairs before March 10, 2025.”
R1T and R1S Affected
The recall notice shows that 19,641 vehicles are being recalled by the company — of whicih 7,031 are R1S units and 12,610 are R1Ts.
The population of vehicles was determined using service records.
Vehicles were excluded if they have not “had service requiring separation and reassembly of a rear suspension toe link joint,” or if they have “received this service after the updated procedure was implemented.”
2022-2025 Production
Rivian produced 42,284 vehicles in 2025 and delivered 42,247 units in the US and Canada.
The company does not distinguish between figures of its R1 models and its electric delivery van (EDV), which it mainly supplies to Amazon.
According to the latest Kelley Blue Book EV Sales Report by Cox Automotive, Rivian sold 28,360 R1S and R1T vehicles and 6,809 EDVs between January 1 and September 30 in the United States.
In the past four years, the company reported production of a total of 173,329 units and 165,200 deliveries.
Last month, Rivian recalled 34,824 electric delivery vans — nearly all units produced — after discovering that repeated misuse could damage the driver’s seat-belt pretensioner cable.
By then, the company said it was not aware of any incidents or injuries linked to the issue.
Recall’s Impact
Rivian sold 17,426 R1T pickup trucks and just 676 R1S SUVs in 2022, reflecting the company’s initial focus on ramping up R1T production before prioritizing the SUV.
By the end of 2023, R1S sales had increased significantly to 24,783 units, while R1T registrations edged up slightly to 17,727 units. In 2024, Rivian listed 26,934 R1S vehicles and 11,085 R1Ts.
With these figures combined — which do not yet consider fourth quarter numbers, and noting that these numbers concern only US sales and are below production numbers — approximately 52,095 R1T vehicles and 72,080 R1S vehicles were registered.
Based on these delivery figures, the recall affects roughly 16% of Rivian’s R1T and R1S vehicles on the road.
