This procedure covers the removal and replacement of both inner and outer tie rod ends on the 2022 Rivian EDV 500 electric delivery van, including alignment considerations.

Warnings

Tools required

Parts

• Outer tie rod end - driver side × 1 — Use OEM specification
• Outer tie rod end - passenger side × 1 — Use OEM specification
• Inner tie rod end - driver side × 1 — Use OEM specification
• Inner tie rod end - passenger side × 1 — Use OEM specification
• Tie rod end castle nuts × 4 — Use OEM specification
• Cotter pins or lock clips × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V accessory battery (located in front compartment) - negative terminal first
4. Loosen front wheel lug nuts while vehicle is on ground
5. Raise front of vehicle and support on manufacturer-approved jack stand positions
6. Remove both front wheels completely
7. Spray all tie rod threads and tapers with penetrating oil and allow to soak for 15 minutes

Procedure

1. 1

   Mark existing tie rod positions
   Before removing any components, use paint marker or tape to mark the exact position of each outer tie rod end on its respective inner tie rod threads. Count and record the number of exposed threads on each side. Take measurements from a fixed point on the steering knuckle to the outer tie rod body. These references will help maintain approximate toe alignment for test driving to the alignment shop.
2. 2

   Remove outer tie rod end cotter pins - driver side
   Locate the castle nut securing the driver side outer tie rod end to the steering knuckle. Straighten and remove the cotter pin or release the lock clip. If cotter pin is corroded, use diagonal cutters to cut it out. Keep a clear path for the tie rod separator tool.
3. 3

   Separate outer tie rod from knuckle - driver side
   Remove the castle nut from the outer tie rod stud. Position the tie rod end puller or pickle fork between the steering knuckle and tie rod end. Tighten the puller or strike the pickle fork to break the taper. Never strike the tie rod end directly. Once the taper breaks, remove the outer tie rod from the knuckle. Support the tie rod to prevent stress on the inner boot.
4. 4

   Remove outer tie rod from inner tie rod - driver side
   Grip the inner tie rod with locking pliers to prevent it from rotating. Use an adjustable wrench on the flats of the outer tie rod and unthread it counterclockwise. Count the exact number of turns required to remove it and record this number. Inspect the inner tie rod threads for damage.
5. 5

   Remove inner tie rod - driver side
   Pull back the steering rack boot to access the inner tie rod connection to the rack. Note the type of connection (threaded or staked). If threaded, use the appropriate size wrench or tie rod tool to unthread the inner tie rod from the steering rack. If staked, the stake must be cut or ground away before unscrewing. Remove the old boot from the rack if it is not integrated with the inner tie rod. Clean the rack threads with a wire brush.
6. 6

   Install new inner tie rod - driver side
   Apply medium-strength thread locker to the inner tie rod threads. Thread the new inner tie rod onto the steering rack by hand, ensuring it starts straight. Tighten to the manufacturer's specification using the appropriate tool. If a staking type connection, properly stake the connection per manufacturer guidelines. Install new rack boot if applicable, ensuring it is properly seated and not twisted. Secure boot clamps.
7. 7

   Install new outer tie rod - driver side
   Thread the new outer tie rod onto the inner tie rod using the same number of turns recorded during removal, aligning with the paint marks made earlier. This maintains approximate toe setting. Do not fully tighten the jam nut yet - it will be adjusted after installation into the knuckle.
8. 8

   Install outer tie rod to knuckle - driver side
   Insert the outer tie rod stud into the steering knuckle taper hole. Install the new castle nut and tighten to specification. The nut must tighten enough to allow cotter pin installation through the castellations. Never loosen the nut to align the pin hole - only tighten further. Install new cotter pin and bend ends to secure. Hold the outer tie rod end and tighten the jam nut against the outer tie rod body to lock the adjustment.
9. 9

   Remove outer tie rod end cotter pin - passenger side
   Repeat the cotter pin removal process on the passenger side. Straighten and remove the cotter pin or release the lock clip from the castle nut securing the outer tie rod end to the steering knuckle.
10. 10

    Separate and remove tie rods - passenger side
    Remove the castle nut and use the tie rod separator tool to break the taper between the outer tie rod and knuckle. Mark the position, then unthread the outer tie rod from the inner tie rod while holding the inner tie rod with locking pliers. Count and record the turns. Access the inner tie rod at the rack and remove it using the same procedure as the driver side.
11. 11

    Install inner and outer tie rods - passenger side
    Apply thread locker and install the new inner tie rod to the steering rack, tightening to specification. Install the rack boot properly. Thread the new outer tie rod onto the inner tie rod using the recorded number of turns to match the original position. Insert the outer tie rod stud into the knuckle and install the castle nut to specification. Install new cotter pin and secure the jam nut.
12. 12

    Verify installation and steering operation
    With wheels still off, visually inspect all tie rod connections for proper seating and secure fasteners. Check that all boots are properly installed without tears or twists. Manually turn the steering wheel lock-to-lock slowly and verify smooth operation without binding. Ensure tie rod ends move freely in their ball joints and that there is no interference with suspension components throughout the full range of motion.

Reassembly

1. Reinstall both front wheels and hand-tighten lug nuts in a star pattern
2. Lower vehicle to ground and torque lug nuts to Rivian specification in star pattern
3. Reconnect 12V accessory battery - positive terminal first, then negative
4. Test electric power steering operation by turning wheel with vehicle running
5. Check for any warning lights or error messages on instrument cluster

Verification

• Test drive vehicle at low speed in a safe area to confirm steering response and no unusual noises or vibrations
• Verify steering wheel returns to center properly after turning
• Check that vehicle tracks reasonably straight (minor deviation is expected until professional alignment)
• Schedule and complete a professional four-wheel alignment as soon as possible - do not delay this critical step
• After alignment, verify no steering play exists by having an assistant rock the steering wheel while you inspect tie rod connections for movement

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