This procedure covers the removal and replacement of the steering coupler connecting the steering column to the steering rack on a 2023 Rivian EDV 500 commercial electric delivery van.

Warnings

Tools required

Parts

• Steering coupler assembly × 1 — Use OEM Rivian part
• Steering coupler pinch bolts × 2 — Use OEM specification
• Steering coupler alignment shims (if applicable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key or disable proximity access
3. Disconnect 12V battery negative terminal and wait 2 minutes for airbag system to discharge
4. Verify high-voltage system is powered down (consult Rivian service manual for HV shutdown procedure)
5. Raise vehicle on lift or securely support on jack stands rated for EV weight
6. Remove driver side front wheel for access to steering components
7. Turn steering wheel to center position and secure with steering wheel holder to prevent rotation
8. Mark exact steering wheel centered position with tape on wheel and dashboard for reference

Procedure

1. 1

   Access steering coupler compartment
   Remove the lower dash panel and steering column covers to access the upper portion of the steering coupler. Remove any necessary trim panels from the driver footwell area. You may need to remove the knee bolster panel for adequate access. Set all fasteners and panels aside in organized manner.
2. 2

   Mark steering shaft alignment
   Before disconnecting anything, use white paint marker to create precise alignment marks across the steering column shaft, steering coupler, and intermediate shaft. Make marks on at least two sides (180 degrees apart) for redundant alignment reference. Photograph the marks for documentation. These marks are critical for maintaining proper steering alignment during reassembly.
3. 3

   Access lower coupler connection
   From underneath the vehicle, locate the steering rack input shaft and lower portion of the steering coupler. Remove any heat shields, protective covers, or wire harness brackets that obstruct access to the lower coupler pinch bolt. Clean the area around the coupler connections to prevent contamination during disassembly.
4. 4

   Remove upper coupler pinch bolt
   Working from inside the vehicle, locate the upper steering coupler pinch bolt connecting the coupler to the steering column shaft. Apply penetrating oil if corrosion is present. Remove the upper pinch bolt completely and set aside (this bolt should be replaced with new hardware). Do not allow the steering wheel to rotate during this process.
5. 5

   Remove lower coupler pinch bolt
   From underneath the vehicle, remove the lower pinch bolt connecting the steering coupler to the steering rack input shaft. Apply penetrating oil if necessary. Remove bolt completely and set aside (replace with new hardware during reassembly). Note the orientation of any washers or spacers.
6. 6

   Separate coupler from steering column
   Using the steering coupler separator tool, carefully separate the upper portion of the coupler from the steering column shaft. The coupler may be tight on the splines. Apply gentle pressure with the separator tool while tapping lightly if needed. Avoid prying in a way that could damage the steering column shaft splines.
7. 7

   Separate coupler from rack input shaft
   From underneath the vehicle, use separator tool to disconnect the lower portion of the coupler from the steering rack input shaft. Work carefully to avoid damaging the rack input shaft seal or boot. If the coupler is seized, apply additional penetrating oil and allow time to soak before applying force.
8. 8

   Remove steering coupler assembly
   Once both connections are separated, carefully maneuver the steering coupler assembly out of the vehicle. This may require removing it from the top through the cabin or from below depending on access. Note the routing and orientation of the coupler for proper installation of the replacement.
9. 9

   Inspect related components
   With coupler removed, inspect the steering column shaft splines, steering rack input shaft splines, and all boots/seals for wear, damage, or contamination. Check that the steering rack input shaft seal is intact and not leaking. Inspect the steering column bearing for excessive play. Replace any damaged components before installing new coupler.
10. 10

    Prepare new steering coupler
    Unpack new OEM steering coupler assembly and verify it matches the removed part. Check that replacement pinch bolts are included or obtain new bolts separately. Apply light coating of clean grease to the steering column shaft and rack input shaft splines (avoid excess that could contaminate seals). Verify steering wheel holder is still in place and wheel has not rotated.
11. 11

    Install new coupler to rack input shaft
    Working from underneath, carefully slide the lower portion of the new steering coupler onto the steering rack input shaft. Align the splines and ensure the coupler slides fully onto the shaft. Rotate the coupler slightly if needed to align splines. Position the pinch bolt hole in the coupler to align with the flat on the input shaft.
12. 12

    Connect coupler to steering column
    From inside the vehicle, carefully slide the upper portion of the coupler onto the steering column shaft, aligning the splines. Reference your alignment marks to ensure proper orientation. The coupler should slide fully onto the shaft with the pinch bolt hole aligned with the flat on the steering column shaft. Verify alignment marks match before proceeding.
13. 13

    Install and torque pinch bolts
    Install new upper pinch bolt into the coupler at the steering column connection. Position bolt to engage the flat on the steering column shaft. Install new lower pinch bolt into the coupler at the rack input shaft connection. Note: Torque specifications not available in database - consult Rivian service manual for proper torque values. Tighten both bolts to specification in sequence recommended by manufacturer. Verify alignment marks still match after tightening.
14. 14

    Verify coupler installation
    With both pinch bolts torqued, visually verify the coupler is fully seated on both shafts and alignment marks are properly positioned. Check that there is no excessive play in the coupler connections. Ensure the coupler does not contact any surrounding components through the full range of steering motion. Reinstall any heat shields, brackets, or protective covers removed during disassembly.

Reassembly

1. Reinstall steering column covers and lower dash panels in reverse order of removal
2. Reinstall driver side front wheel and torque lug nuts to Rivian specification
3. Lower vehicle to ground
4. Remove steering wheel holder
5. Reconnect 12V battery negative terminal
6. Power up vehicle and verify all dashboard warning lights function normally then extinguish

Verification

• With vehicle still on lift or supported, start vehicle and verify electric power steering system initializes without fault codes
• Turn steering wheel slowly from lock to lock while observing coupler connections for proper operation and no binding
• Connect Rivian diagnostic tool and perform steering angle sensor calibration per manufacturer procedure
• Clear any stored diagnostic codes related to steering system
• Perform careful test drive in safe area at low speed, verifying steering response is normal with no unusual noises or vibrations
• Check steering wheel returns to center properly after turns
• Verify steering wheel is centered when driving straight
• Re-scan for diagnostic codes after test drive to ensure no new faults are present

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