Tie Rod Assembly

This procedure covers the removal and replacement of the tie rod assembly on a 2023 Rivian EDV 500, including outer tie rod end and inner tie rod where applicable.

Warnings

Tools required

Parts

• Tie rod end (left or right as needed) × 1 — Use OEM specification
• Tie rod jam nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels to prevent vehicle movement
3. Loosen wheel lug nuts while vehicle is on ground (do not remove)
4. Lift front of vehicle using approved lift points and secure on jack stands
5. Remove wheel and tire assembly from affected side
6. Spray tie rod end castle nut and threads with penetrating lubricant if corroded
7. Take reference measurements of tie rod length from jam nut to tie rod end for approximate alignment reference

Procedure

1. 1

   Remove cotter pin and castle nut
   Locate the tie rod end castle nut at the steering knuckle connection. Remove and discard the cotter pin using pliers or wire cutters. Using an appropriate socket, remove the castle nut from the tie rod end stud. Do not fully remove the nut initially; loosen it but leave it threaded on a few turns to protect the threads during separation.
2. 2

   Separate tie rod end from steering knuckle
   Using a tie rod end separator or pickle fork, separate the tie rod end taper from the steering knuckle. Position the separator between the knuckle and tie rod end, then strike or apply pressure according to tool design. Once the taper breaks free, remove the castle nut completely and pull the tie rod end stud out of the knuckle. Avoid damaging the steering knuckle boot or surrounding components.
3. 3

   Mark tie rod position
   Before loosening the jam nut, mark the position of the tie rod end on the tie rod threads using a paint marker or by counting exposed threads. This reference will help maintain approximate toe alignment during reassembly. Measure and record the distance from the jam nut to the end of the tie rod end for verification.
4. 4

   Loosen jam nut
   Using two wrenches (one to hold the tie rod, one for the jam nut), loosen the jam nut that secures the tie rod end to the inner tie rod or adjustment sleeve. Break the jam nut free but do not remove it completely yet. The jam nut may require significant force if it has been previously torqued and secured with thread locker.
5. 5

   Remove outer tie rod end
   Thread the outer tie rod end off the inner tie rod by rotating it counterclockwise. Count the number of turns required for complete removal or reference your measurement marks. Keep the jam nut in place on the inner tie rod threads. Inspect the threads on the inner tie rod for damage or excessive wear.
6. 6

   Inspect steering components
   With the tie rod end removed, inspect the steering knuckle taper bore for damage, scoring, or contamination. Check the inner tie rod boot for tears or leaks if visible. Inspect the steering rack bellows boot for damage. Clean the knuckle taper bore with a wire brush if necessary. Replace any damaged components as needed.
7. 7

   Prepare new tie rod end
   Clean the threads on the inner tie rod with a wire brush. Apply a small amount of anti-seize compound to the inner tie rod threads if recommended by manufacturer. Thread the jam nut onto the new tie rod end approximately to the position marked on the old part.
8. 8

   Install new tie rod end
   Thread the new tie rod end onto the inner tie rod clockwise, counting turns or aligning to your reference marks. Install it to the same depth as the original component based on your measurements and thread count. The goal is to approximate the previous toe setting as closely as possible.
9. 9

   Install tie rod end into knuckle
   Insert the tie rod end stud into the steering knuckle taper. Ensure the stud seats fully into the taper bore. Install the castle nut and hand-tighten. Using a torque wrench, tighten the castle nut to manufacturer specification (refer to Rivian service documentation as database values are unavailable). If necessary, continue tightening to align castle nut slots with the stud hole, never back off to align.
10. 10

    Install new cotter pin
    Insert a new cotter pin through the castle nut and tie rod end stud hole. Bend the cotter pin legs in opposite directions to secure it properly. Ensure the cotter pin is fully seated and cannot work loose. Verify the castle nut cannot rotate with the cotter pin installed.
11. 11

    Tighten jam nut
    Using two wrenches, hold the tie rod end body to prevent it from rotating while tightening the jam nut against the tie rod end. Apply medium-strength thread locking compound to the jam nut threads if specified by manufacturer. Torque the jam nut to manufacturer specification (consult Rivian service documentation). Verify the tie rod end does not rotate during this operation.
12. 12

    Verify installation
    Inspect all connections to ensure proper assembly. Verify the tie rod end stud is fully seated in the knuckle taper, castle nut is properly torqued, and cotter pin is secure. Check that the jam nut is tight and the tie rod end cannot rotate. Verify no components are contacting suspension parts through full steering range by rotating steering wheel lock to lock.

Reassembly

1. Reinstall wheel and tire assembly onto hub
2. Thread lug nuts by hand to prevent cross-threading
3. Lower vehicle until tire just contacts ground to prevent wheel rotation
4. Torque lug nuts to manufacturer specification in a star pattern
5. Fully lower vehicle and remove jack stands
6. Remove wheel chocks

Verification

• Test drive vehicle at low speed in a safe area to verify steering operation
• Listen for any unusual noises or clunking from the tie rod area during steering input
• Check for proper steering return to center after turns
• Schedule immediate professional wheel alignment to set proper toe angle and prevent tire wear
• After alignment, verify steering wheel is centered and vehicle tracks straight
• Re-check jam nut torque after 50-100 miles of driving

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