Rivian Issues Major Recall for 35K Delivery Vans Due to Seatbelt Damage Risk

Rivian is issuing a safety recall for nearly 35,000 commercial electric vans in the United States after identifying a potential defect in the driver’s seat belt pretensioner cable. The issue, disclosed in new NHTSA filings, stems from repeated misuse, specifically, drivers sitting on a buckled seat belt instead of wearing it properly. While the company reports no related injuries or accidents, the recall covers the majority of its Electric Delivery Van (EDV) fleet, most of which operates under Amazon.

Seatbelt misuse triggers inspection campaign

The recall affects 34,824 Rivian commercial vans, with neither the R1S SUV nor the R1T pickup included. According to Rivian, the problem occurs when drivers repeatedly sit on the seat belt to silence the warning chime while entering and exiting the vehicle dozens of times during delivery routes. This behavior can damage the pretensioner cable and compromise crash protection, according to InsideEVs.

Rivian will inspect affected vehicles and replace seat belt pretensioner assemblies when necessary. The company has also deployed an over-the-air software update designed to detect seat belt misuse, helping prevent future damage. The update is meant to keep vehicles fully operational while minimizing downtime for commercial fleets.

Impact on Rivian’s van program and fleet customers

Rivian’s commercial van program has been central to the company’s strategy since production began in 2021 as part of its major contract with Amazon to deliver 100,000 units by 2030. More than 20,000 have been delivered so far, and sales data shows the vehicle continues to lead the light commercial EV segment, outperforming competitors like Ford’s E-Transit and GM’s BrightDrop lineup.

Although the exclusivity agreement with Amazon ended in 2023, the recall primarily affects Amazon’s fleet. Rivian’s swift OTA response and structured inspection procedures underscore how EV manufacturers are increasingly relying on software solutions to manage fleetwide safety issues with minimal disruption.

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