This procedure covers the replacement of the steering rack and pinion boots on a 2022 Rivian EDV 500 dual motor AWD electric delivery van to prevent contamination and maintain steering system integrity.

Warnings

Tools required

Parts

• Steering rack boot kit (left and right) × 1 — Use OEM specification
• Boot clamps (small and large per side) × 4 — Included in boot kit or Use OEM specification
• Outer tie rod end (if damaged during removal) × 2 — Use OEM specification
• Steering rack grease × 1 — Use OEM specification or equivalent lithium-based grease

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V auxiliary battery negative terminal
4. Follow manufacturer procedure to disable high-voltage system and apply lockout/tagout
5. Lift front of vehicle and secure on jack stands rated for EDV 500 weight
6. Remove front wheels
7. Clean steering rack area with parts cleaner to identify all connections
8. Photograph or document current tie rod position and thread engagement for reference

Procedure

1. 1

   Mark alignment reference points
   Before loosening any components, use a marker or paint pen to mark the position of the outer tie rod end relative to the inner tie rod. Count and record the number of visible threads on the inner tie rod past the outer tie rod end jam nut. Measure the overall tie rod length from inner ball joint center to outer ball joint center for reference.
2. 2

   Remove outer tie rod end from knuckle
   Remove the cotter pin (if equipped) and loosen but do not remove the outer tie rod end castle nut. Use a tie rod separator or pickle fork to separate the outer tie rod end from the steering knuckle. Remove the castle nut completely and remove the tie rod end from the knuckle taper. Avoid hammering directly on threads.
3. 3

   Loosen tie rod jam nut and outer tie rod
   Loosen the jam nut securing the outer tie rod end to the inner tie rod using an appropriate wrench. Count the number of turns required to completely unthread the outer tie rod end from the inner tie rod, or reference your alignment marks. Remove the outer tie rod end and set aside. Keep track of left and right side components separately.
4. 4

   Remove outer boot clamps
   Locate the boot clamps on the outer end of the rack boot (near the inner tie rod). Use boot clamp pliers or carefully cut the clamps with side cutters to remove them. Note the orientation and position of the clamps for reinstallation. Discard old clamps if they are crimped type.
5. 5

   Remove inner boot clamps and boot
   Locate the boot clamps on the inner end of the rack boot where it connects to the steering rack housing. Remove these clamps using the same method as the outer clamps. Carefully slide the old boot off the inner tie rod and steering rack. Inspect the inner tie rod for damage or excessive wear. Clean the steering rack housing bellows groove with a wire brush and parts cleaner.
6. 6

   Inspect steering rack and inner tie rod
   With the boot removed, thoroughly inspect the steering rack surface and inner tie rod ball joint for damage, corrosion, or contamination. Check for grease leakage from the rack housing seal. If the rack is dry or contaminated, additional service may be required. Clean all surfaces that will contact the new boot with parts cleaner and allow to dry.
7. 7

   Apply grease to steering rack
   Apply a liberal amount of steering rack grease or white lithium grease to the steering rack surface where the boot will contact. Ensure the inner tie rod ball joint boot area is also properly greased. Do not use excessive grease that will cause the boot to balloon, but ensure adequate coverage for protection.
8. 8

   Install new boot and inner clamp
   Slide the new boot onto the steering rack housing, ensuring it is fully seated in the bellows groove on the rack housing. Install the inner boot clamp in the correct groove and position it properly. Use boot clamp pliers to secure the clamp tightly, ensuring the boot forms a proper seal against the rack housing. Verify the boot is not twisted or pinched.
9. 9

   Install outer clamp
   Stretch the outer end of the boot over the inner tie rod and position it in the proper groove. Ensure the boot is not twisted and has adequate slack to allow for suspension travel without binding. Install the outer boot clamp and secure it tightly using boot clamp pliers. Check that the boot can expand and contract freely without restriction.
10. 10

    Reinstall outer tie rod end
    Thread the outer tie rod end back onto the inner tie rod, using your alignment marks and thread count documentation to return it to the original position. This should restore the approximate wheel alignment. Do not fully tighten the jam nut yet.
11. 11

    Reconnect tie rod end to knuckle
    Insert the outer tie rod end ball stud into the steering knuckle taper. Install the castle nut and tighten to the proper specification per service manual (specification not available in current database - consult manufacturer documentation). Install a new cotter pin if equipped. Ensure the tie rod end is properly seated in the knuckle taper.
12. 12

    Tighten jam nut and verify boot
    Hold the outer tie rod end with a wrench to prevent it from turning and tighten the jam nut securely. Verify the boot is properly positioned and not twisted. Cycle the steering from lock to lock slowly while observing the boot to ensure it does not bind, tear, or pop out of position. Make corrections if necessary.
13. 13

    Repeat for opposite side
    Repeat steps 1 through 12 for the opposite side steering rack boot. Ensure both sides are installed symmetrically and both boots move freely through the full range of steering and suspension travel.

Reassembly

1. Reinstall front wheels and torque lug nuts to manufacturer specification
2. Lower vehicle to ground
3. Reconnect 12V auxiliary battery negative terminal
4. Follow manufacturer procedure to re-enable high-voltage system and remove lockout/tagout
5. Start vehicle and verify electric power steering system operates normally with no warning lights

Verification

• Turn steering wheel lock-to-lock and verify smooth operation with no binding or unusual noises
• Visually inspect both rack boots to confirm they are properly seated and not torn or leaking
• Check that boots expand and contract properly during steering movement without ballooning or collapsing
• Test drive vehicle at low speed and verify steering response is normal and tracking is straight
• Schedule a professional wheel alignment to verify toe settings are within specification, as tie rod positions may have shifted slightly during the procedure

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