Remove and replace the intermediate steering shaft that connects the steering column to the steering rack on a 2022 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM specification
• Steering shaft pinch bolt (upper) × 1 — Use OEM specification
• Steering shaft pinch bolt (lower) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Ensure front wheels are pointed straight ahead
3. Chock rear wheels securely
4. Open hood and disconnect 12V negative battery terminal, wait 3 minutes for airbag system to fully discharge
5. Raise front of vehicle with floor jack and support on jack stands at manufacturer-specified lift points
6. Remove front underbody panels/skid plates if equipped to access steering components from below
7. Lock steering wheel in center position using steering wheel lock or tape to prevent rotation

Procedure

1. 1

   Mark shaft alignment positions
   Using a white paint marker, create alignment marks across all steering shaft joints including the upper shaft-to-column connection, the intermediate shaft U-joints, and the lower shaft-to-rack connection. These marks are critical for maintaining proper steering alignment during reassembly. Take photos from multiple angles for reference.
2. 2

   Access upper steering shaft connection
   From inside the vehicle, remove the lower dash panel or knee bolster to access the steering column area. You may need to remove the driver's side footwell trim panels. Locate the upper pinch bolt that secures the intermediate shaft to the steering column shaft.
3. 3

   Remove upper pinch bolt
   Apply penetrating oil to the upper pinch bolt if corrosion is present. Using the appropriate socket, remove the upper pinch bolt that clamps the intermediate shaft to the steering column. Keep this bolt if reusing, or discard if replacing with new hardware. Note the bolt orientation for reinstallation.
4. 4

   Access lower steering shaft connection
   Working from underneath the vehicle with adequate lighting, locate where the intermediate shaft connects to the steering rack input shaft. This connection is typically located at the firewall/bulkhead area near the steering rack. Clean the area around the lower pinch bolt with a wire brush if necessary.
5. 5

   Remove lower pinch bolt
   Apply penetrating oil to the lower pinch bolt if needed. Remove the lower pinch bolt that secures the intermediate shaft to the steering rack input shaft. Support the intermediate shaft as you remove the bolt to prevent it from falling.
6. 6

   Separate intermediate shaft from steering column
   Working from inside the vehicle, carefully slide the upper portion of the intermediate shaft off the steering column splined shaft. The shaft should slide straight back toward the firewall. If it's stuck, gently wiggle while pulling - do not use excessive force or pry against the column itself.
7. 7

   Separate intermediate shaft from steering rack
   From underneath the vehicle, carefully separate the lower portion of the intermediate shaft from the steering rack input shaft. The shaft should pull away from the splined connection. If resistance is encountered, verify the pinch bolt is completely removed and use gentle wiggling motion.
8. 8

   Remove intermediate shaft assembly
   Guide the intermediate shaft assembly out through the firewall area. The shaft typically needs to be angled and rotated to clear the firewall opening, brake lines, and other components. Work carefully to avoid damaging the shaft boot or surrounding components. Remove the shaft completely from the vehicle.
9. 9

   Inspect related components
   With the intermediate shaft removed, inspect the steering column shaft and steering rack input shaft for damage, excessive wear, or corrosion. Check that the splines are clean and undamaged. Inspect the firewall seal/boot for tears or damage. Clean the splined shafts with a wire brush if corrosion is present.
10. 10

    Install new intermediate shaft assembly
    Guide the new intermediate shaft through the firewall opening, angling as necessary to clear all components. Align the shaft so both the upper and lower connections are accessible. Ensure any rubber boots or seals are properly positioned and not pinched.
11. 11

    Connect shaft to steering rack
    Align the lower portion of the intermediate shaft with the steering rack input shaft, matching the alignment marks made during disassembly. Slide the shaft onto the splined connection until fully seated. The shaft should slide on smoothly - do not force it.
12. 12

    Install lower pinch bolt
    Install the new or reused lower pinch bolt through the clamp. Ensure the bolt passes through the notch or detent in the steering rack input shaft. Hand-tighten the bolt initially. Verify alignment marks are still properly aligned before final tightening. Torque the bolt to manufacturer specification (consult service manual as specification not provided in database).
13. 13

    Connect shaft to steering column
    From inside the vehicle, align the upper portion of the intermediate shaft with the steering column shaft, matching your alignment marks. Slide the shaft onto the column splines until fully seated. Verify the shaft is engaged properly and alignment marks match.
14. 14

    Install upper pinch bolt
    Install the new or reused upper pinch bolt through the clamp at the column connection. Ensure the bolt passes through the notch or detent in the steering column shaft. Hand-tighten initially, verify alignment marks are correct, then torque to manufacturer specification (consult service manual as specification not provided in database).
15. 15

    Verify installation and test
    Double-check that both pinch bolts are properly torqued and that all alignment marks are correctly positioned. Remove steering wheel lock. Reinstall all interior panels, underbody panels, and skid plates. Reconnect the 12V battery. Lower vehicle to ground. Start the vehicle and verify the electric power steering system initializes without error codes. Turn the steering wheel lock-to-lock slowly to verify smooth operation and proper function. Test drive at low speed in a safe area to confirm proper steering operation before returning to normal service.

Reassembly

1. Ensure both upper and lower pinch bolts are torqued to specification with alignment marks properly matched
2. Verify steering wheel lock or tape is removed before testing steering
3. Confirm all interior trim panels and underbody panels are securely reinstalled
4. Check that firewall seal/boot is properly seated with no tears or gaps

Verification

• Confirm steering wheel returns to center position smoothly after turning in both directions
• Verify no unusual noises, binding, or looseness in steering operation
• Check that electric power steering system shows no warning lights or error codes on instrument cluster
• Test drive vehicle at various speeds to ensure proper steering feel and response
• Verify steering wheel is centered when driving straight with no pulling to either side
• Inspect both pinch bolt connections after test drive to ensure they remain tight with no movement

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