The National Highway Traffic Safety Administration (NHTSA) has initiated an investigation into Rivian’s R1S and R1T vehicles, focusing on potential defects in rear toe links. This probe involves 114,922 vehicles from model years 2022 to 2025, following reports of toe link separation during driving.
The investigation was sparked by two complaints concerning 2023-2024 R1S vehicles experiencing toe link failures. Both instances involved the left rear toe link separating while the vehicle was in motion, leading to swerving across traffic lanes. One of these incidents resulted in a collision with another vehicle and a roadside barrier.
In each case, the bolt holding the toe link fractured. NHTSA’s Office of Defects Investigation has gathered various data including repair histories, onboard video, images of the damaged parts, and police reports from the incidents. Fortunately, no injuries or fatalities have been reported.
Service Background and Component Details
The two vehicles involved had differing service histories; one had been serviced prior, while the other had been in a previous accident. Despite this, both vehicles operated without issues for months before the failures. The toe link is a crucial suspension component that maintains rear-wheel alignment, and its failure can lead to a sudden loss of control.
Previous Recall Information
This current investigation follows a recall issued in January for nearly 20,000 R1 vehicles due to the same issue. The recall affected 19,641 vehicles, including 7,031 R1S SUVs and 12,610 R1T pickups, which had undergone toe link service before improved procedures were introduced in March 2025.
In March 2025, Rivian identified the sensitivity of the toe link joint to service procedures and subsequently updated its instructions. The January recall extended the improved repair approach to vehicles serviced before this change. NHTSA’s preliminary evaluation aims to assess the toe link joint’s sensitivity to road and service conditions.
The investigation’s scope, covering 114,922 vehicles, is significantly larger than the prior recall, indicating a broader examination of potential failures beyond those related to faulty service work.
Rivian’s R1 Production and Incentives
In the first quarter, Rivian delivered 10,365 vehicles globally, marking a 20% year-over-year increase. However, this growth was primarily driven by commercial van sales rather than the R1 models. Rivian has extended its May leasing incentives for the R1S and R1T models through June 4, offering significant reductions in monthly lease rates and additional discounts for Memorial Day sales.
Upcoming R2 Launch
The investigation coincides with Rivian’s impending launch of its R2 mid-size SUV, expected to boost sales in the latter half of 2026. Rivian has already begun production of the R2 at its Illinois plant, with deliveries starting in June. The R2 Performance Launch Edition is currently available for configuration, with additional trims planned for release in the coming years.
Production and Safety Actions
Rivian produced 42,284 vehicles in 2025, with 42,247 delivered across North America. Over the past four years, the company has built 173,329 vehicles and delivered 165,200. The current toe link investigation adds to a series of safety actions, including a December recall of nearly all electric delivery vans over potential seat-belt issues.
Original Story at eletric-vehicles.com