This procedure covers the removal and replacement of the intermediate steering shaft on a 2023 Rivian EDV 500, connecting the steering column to the steering gear.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM specification
• Steering shaft coupler bolts × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground with front wheels pointed straight ahead
2. Apply parking brake and place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal and wait 5 minutes for airbag system to discharge
4. Raise front of vehicle and support securely on jack stands
5. Remove front skid plate or underbody panels to access steering components if equipped

Procedure

1. 1

   Access the intermediate steering shaft
   From underneath the vehicle, locate the intermediate steering shaft between the steering column and the steering gear. Use a flashlight to identify the upper and lower coupling points. Clean any dirt or debris from the coupling bolt areas with a wire brush.
2. 2

   Mark shaft alignment
   Using a paint marker or chalk, make alignment marks across both the upper coupling (steering column to intermediate shaft) and lower coupling (intermediate shaft to steering gear). Mark both the shaft and the mating components to ensure proper reinstallation alignment. These marks are critical for maintaining steering geometry.
3. 3

   Remove upper coupling fasteners
   Locate the upper coupling pinch bolt or bolts connecting the intermediate shaft to the steering column. Support the intermediate shaft with one hand and remove the upper coupling fastener(s). Note the orientation and position of any washers or spacers.
4. 4

   Remove lower coupling fasteners
   Locate the lower coupling pinch bolt or bolts connecting the intermediate shaft to the steering gear input shaft. Remove the lower coupling fastener(s) while supporting the intermediate shaft to prevent it from falling.
5. 5

   Separate upper coupling
   Carefully pry or separate the upper coupling from the steering column shaft. If the coupling is tight, use a pry bar or steering shaft separator tool to gently separate the connection. Do not use excessive force that could damage the splines.
6. 6

   Separate lower coupling and remove shaft
   Similarly separate the lower coupling from the steering gear input shaft. Once both ends are free, carefully maneuver the intermediate steering shaft out of the vehicle. Note the routing path and any clearance points for reinstallation.
7. 7

   Inspect components
   Inspect the steering column shaft and steering gear input shaft splines for wear, damage, or corrosion. Check the rubber coupling boots for tears or deterioration. Clean the splined surfaces if necessary. Replace any damaged components before proceeding.
8. 8

   Prepare new intermediate shaft
   Unpack the new intermediate steering shaft and verify it matches the original. Apply a thin coat of white lithium grease to the splined connections at both ends of the new shaft. Do not over-grease as this can attract dirt.
9. 9

   Install intermediate shaft
   Position the new intermediate shaft into the vehicle following the same routing path as the original. Align the lower coupling with the steering gear input shaft first, ensuring the alignment marks line up (or that the shaft is at the proper position if using a new shaft). Slide the coupling onto the splines but do not fully seat yet.
10. 10

    Connect upper coupling
    Align the upper coupling with the steering column shaft, matching your alignment marks. Slide the coupling onto the steering column splines. Ensure both upper and lower couplings are properly seated on their respective shafts before installing fasteners.
11. 11

    Install and torque fasteners
    Install the lower coupling pinch bolt(s) and hand-tighten. Install the upper coupling pinch bolt(s) and hand-tighten. Verify alignment marks are still matched. Torque all coupling fasteners according to Rivian specifications (consult service manual for exact values as none are provided in this database). Ensure proper bolt orientation with any locking features engaged.
12. 12

    Verify installation
    Check that both couplings are fully seated and secure. Attempt to move the intermediate shaft by hand to confirm there is no play or looseness at either coupling. Verify the shaft does not contact any surrounding components throughout its range of motion.

Reassembly

1. Reinstall any underbody panels or skid plates that were removed
2. Lower vehicle from jack stands
3. Reconnect 12V battery negative terminal
4. Verify steering wheel is still centered with wheels straight ahead

Verification

• Start vehicle and verify no warning lights related to steering system appear on instrument cluster
• Turn steering wheel lock-to-lock while stationary and listen for any unusual noises, binding, or clicking from the intermediate shaft area
• Perform a slow-speed test drive in a safe area, checking for proper steering response and centering
• Verify steering wheel returns to center after turns
• Re-check all coupling fastener torque after test drive
• If steering angle sensor fault appears, perform steering angle sensor calibration using Rivian diagnostic software

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