This procedure covers the removal and replacement of the outer tie rod end on a 2023 Rivian EDV 500, including disconnection from the steering knuckle and adjustment for proper wheel alignment.

Warnings

Tools required

Parts

• Outer tie rod end × 1 — Use OEM specification
• Tie rod end castle nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Power off vehicle completely and remove key fob from vehicle interior
4. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes for system capacitor discharge
5. Loosen wheel lug nuts while vehicle is still on ground
6. Raise front of vehicle with floor jack at designated lift point
7. Support vehicle securely on jack stands at frame lift points
8. Remove wheel and tire assembly completely

Procedure

1. 1

   Mark existing tie rod position
   Before removing the outer tie rod end, use a permanent marker to mark the position of the tie rod end on the inner tie rod threads. Count and record the exact number of threads visible between the jam nut and the tie rod end body. This reference will help maintain approximate toe alignment during reassembly.
2. 2

   Apply penetrating lubricant
   Spray penetrating lubricant on the outer tie rod end castle nut, the tie rod end taper at the steering knuckle, and the jam nut threads. Allow 10-15 minutes for penetration to ease removal and prevent damage to threads or tapers.
3. 3

   Remove cotter pin and castle nut
   Straighten and remove the cotter pin from the castle nut on the tie rod end stud. Using a 21mm wrench, remove the castle nut completely from the tie rod end stud. Set aside the old castle nut as it should be replaced with a new one.
4. 4

   Separate tie rod end from steering knuckle
   Using a tie rod end separator tool or pickle fork, carefully separate the tie rod end taper from the steering knuckle. Position the separator between the steering knuckle and tie rod end housing. Strike the tool firmly or use threaded separator to break the taper. Avoid damaging the steering knuckle bore or CV boot during separation.
5. 5

   Loosen jam nut
   Using a 19mm wrench on the jam nut and an adjustable wrench or locking pliers to hold the inner tie rod flat surfaces, loosen the jam nut. Do not remove the jam nut completely - loosen it enough to allow rotation of the outer tie rod end. Note the position of the jam nut relative to your alignment marks.
6. 6

   Remove outer tie rod end
   While holding the inner tie rod steady with locking pliers or adjustable wrench on the flats, unthread the outer tie rod end by rotating it counterclockwise. Count the number of complete rotations required for removal. This count provides an additional reference for installation depth.
7. 7

   Clean threads and inspect components
   Use a wire brush to clean the threads on the inner tie rod. Inspect the inner tie rod threads, jam nut, and steering knuckle taper bore for damage, corrosion, or wear. Check the steering knuckle taper seat for scoring or deformation. Clean the taper seat thoroughly to ensure proper new tie rod end seating.
8. 8

   Install new outer tie rod end
   Apply a light coat of thread sealant to the inner tie rod threads if specified by manufacturer. Thread the new outer tie rod end onto the inner tie rod clockwise, counting rotations to match the removal count. Stop when the tie rod end reaches the alignment mark made during disassembly. The visible thread count should match your initial measurement.
9. 9

   Install tie rod end into steering knuckle
   Insert the outer tie rod end stud into the steering knuckle taper bore. Ensure the taper is fully seated by checking that the tie rod end housing contacts the knuckle boss. The stud should pass through the knuckle cleanly without binding.
10. 10

    Install and tighten castle nut
    Install the new castle nut onto the tie rod end stud. Tighten to the manufacturer's specification using a torque wrench. Since no torque specification is available in the database, refer to the Rivian service manual or typical specification of 50-55 ft-lbs for this class vehicle. Continue tightening if necessary to align castle nut slots with cotter pin hole - never loosen to align.
11. 11

    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 - one leg should wrap around the nut, the other should be bent back over the top. Ensure the cotter pin is fully seated and secure.
12. 12

    Tighten jam nut
    While holding the outer tie rod end to prevent rotation, tighten the jam nut against the outer tie rod end body using a 19mm wrench. Apply adequate torque to lock the adjustment - typically 35-50 ft-lbs for this application. Verify the outer tie rod end does not rotate during jam nut tightening.

Reassembly

1. Reinstall wheel and tire assembly, hand-threading lug nuts
2. Lower vehicle until tire contacts ground but does not bear full weight
3. Tighten lug nuts in star pattern to manufacturer specification (typically 130-140 ft-lbs for Rivian EDV)
4. Lower vehicle completely and remove jack stands
5. Reconnect 12V auxiliary battery negative terminal
6. Perform final torque verification of all fasteners

Verification

• Start vehicle and verify electric power steering system functions normally with no warning lights
• Turn steering wheel lock-to-lock while stationary to verify smooth operation and no binding
• Verify tie rod end has no play by attempting to move it by hand - it should be solid with no looseness
• Test drive vehicle at low speed in safe area to confirm steering response and no unusual noises
• Schedule professional wheel alignment immediately - vehicle toe setting has been disturbed and driving with improper alignment will cause rapid tire wear
• After alignment, verify steering wheel is centered when driving straight and vehicle tracks true without pulling

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