Steering Shaft - Upper

This procedure covers removal and replacement of the upper steering shaft on a 2023 Rivian EDV 500 electric delivery van, including disconnection from the steering column and intermediate shaft.

Warnings

Tools required

Parts

• Upper steering shaft assembly × 1 — Use OEM specification
• Steering shaft coupling bolt(s) × 2 — Use OEM specification
• Steering shaft pinch bolt × 1 — Use OEM specification
• Lock washer or retaining clip (if applicable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is powered off and key fob is at least 15 feet away from vehicle
3. Disconnect 12V battery negative terminal and wait at least 3 minutes for airbag system capacitors to discharge
4. Turn steering wheel to center position (wheels straight ahead)
5. Remove driver's side lower dashboard trim panels and knee bolster to access steering column
6. Document or photograph routing of any wiring harnesses near the steering column

Procedure

1. 1

   Remove lower column covers
   Remove the upper and lower steering column covers by releasing the retaining clips. Carefully pull the covers away from the column, taking care not to damage the trim or wiring for the column-mounted controls. Disconnect any electrical connectors if necessary for complete removal.
2. 2

   Mark shaft alignment
   Using a paint marker, create alignment marks across the upper steering shaft and intermediate shaft coupling joint. Make marks on both the shaft splines and the coupling body to ensure exact reinstallation positioning. Take a photo for reference.
3. 3

   Disconnect electrical connections
   Locate and disconnect any electrical connectors on the steering column including clockspring connector, steering angle sensor, and column lock actuator if equipped. Label each connector or take photos to ensure correct reconnection. Secure disconnected wiring away from work area.
4. 4

   Remove upper shaft pinch bolt
   Locate the pinch bolt or coupling bolts at the connection between the upper steering shaft and intermediate shaft. Remove the pinch bolt completely. If the connection uses a clamp-style coupling, fully loosen the bolt until the clamp opens. Note the bolt orientation and any washers for reinstallation.
5. 5

   Remove steering column mounting bolts
   Support the steering column with one hand or have an assistant hold it. Remove the steering column mounting bolts (typically 2-4 bolts) that secure the column bracket to the dash support structure. Keep track of bolt locations as they may be different lengths.
6. 6

   Separate intermediate shaft connection
   With the pinch bolt removed, carefully separate the upper steering shaft from the intermediate shaft by pulling straight back. If the connection is tight, use a small pry bar to gently spread the coupling clamp while pulling. Do not use excessive force which could damage the splines.
7. 7

   Remove upper steering shaft from column
   Carefully lower or tilt the steering column as needed to provide clearance. Slide the upper steering shaft up and out of the column assembly, taking care not to damage any remaining wiring or the clockspring mechanism. The shaft may need to be angled or rotated slightly to clear mounting brackets.
8. 8

   Inspect components
   Inspect the intermediate shaft splines, column bearings, and mounting points for wear, damage, or debris. Check the clockspring for any signs of damage. Clean any debris from the column and shaft mounting areas. Verify the new upper steering shaft matches the removed unit exactly.
9. 9

   Install new upper steering shaft
   Insert the new upper steering shaft into the steering column from above, ensuring proper orientation. The shaft should slide smoothly through the column bearings. Align any flats or keyways as required. Position the shaft so the lower splined end is accessible for connection to the intermediate shaft.
10. 10

    Reconnect to intermediate shaft
    Carefully align the upper steering shaft splines with the intermediate shaft, matching the alignment marks made during disassembly. Slide the shafts together ensuring full engagement of the splines. The coupling clamp should fit properly around both shaft ends.
11. 11

    Install column mounting bolts
    Raise the steering column into position against the dash support bracket. Install all steering column mounting bolts finger-tight first to ensure proper alignment. Tighten the mounting bolts evenly in a cross-pattern to manufacturer specification. Verify column is secure and properly positioned.
12. 12

    Install and torque pinch bolt
    Install the new pinch bolt or coupling bolt(s) at the upper shaft to intermediate shaft connection. Ensure any washers or lock features are properly positioned. Tighten the pinch bolt(s) to manufacturer specification. Verify the coupling clamp is fully seated and there is no play in the connection.
13. 13

    Reconnect electrical connections
    Reconnect all electrical connectors to the steering column in reverse order of removal, including clockspring, steering angle sensor, and column lock actuator. Ensure each connector clicks fully into place and any locking tabs are engaged. Verify wiring is properly routed and not pinched.
14. 14

    Reinstall column covers and trim
    Reinstall the upper and lower steering column covers, ensuring all retaining clips snap into place. Reinstall the lower dashboard trim panels and knee bolster. Verify all trim pieces are secure and properly aligned.

Reassembly

1. Reconnect the 12V battery negative terminal
2. Power on the vehicle and verify the steering wheel is centered with wheels straight ahead
3. Verify all dashboard warning lights operate normally during startup and then extinguish
4. Check that all steering column controls (turn signals, wipers, etc.) function properly

Verification

• Start vehicle and verify no steering-related warning lights or messages appear on the instrument cluster
• Perform a steering angle sensor calibration using Rivian diagnostic software or follow the vehicle's self-calibration procedure
• Turn steering wheel lock-to-lock while stationary to verify smooth operation with no binding, clicking, or unusual noises
• Test drive vehicle at low speed in a safe area to confirm proper steering response and alignment
• Verify electric power steering assist is functioning normally
• Confirm airbag light is not illuminated and all safety systems are operational
• Verify steering returns to center smoothly and there is no excessive play or looseness in the steering shaft connection

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