This procedure covers the removal and replacement of both inner and outer tie rods on the 2023 Rivian EDV 500, including steering alignment considerations.

Warnings

Tools required

Parts

• Inner tie rod (left) × 1 — Use OEM Rivian specification
• Inner tie rod (right) × 1 — Use OEM Rivian specification
• Outer tie rod end (left) × 1 — Use OEM Rivian specification
• Outer tie rod end (right) × 1 — Use OEM Rivian specification
• Cotter pins (if equipped) × 4 — Various sizes as needed
• Tie rod dust boots × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Verify vehicle is fully powered down and in Park mode
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Raise front of vehicle with floor jack at designated lift points
6. Support vehicle securely on jack stands rated for EV weight at frame lift points
7. Remove both front wheels completely
8. Spray all tie rod connections with penetrating oil and allow 10-15 minutes to soak
9. Take photos of tie rod orientation and positioning for reference

Procedure

1. 1

   Measure and document tie rod position
   Before removing any components, measure the exposed thread length on the outer tie rod ends from the jam nut to the end of the threads. Record these measurements for both sides. Count the number of visible threads or mark the position with paint to ensure proper initial toe setting during reassembly. This is critical since alignment will be performed afterward.
2. 2

   Remove outer tie rod end castle nut
   On the steering knuckle, remove cotter pin from the outer tie rod end castle nut if equipped. Use 19mm socket to remove the castle nut from the tie rod stud. Do not allow the tie rod to spin while loosening. Keep hardware organized by side (left/right).
3. 3

   Separate outer tie rod from steering knuckle
   Use tie rod end separator or pickle fork to break the taper between the tie rod stud and steering knuckle. Insert tool between knuckle and tie rod end, then strike or press firmly to separate. Avoid damaging the steering knuckle threads or rubber boot. If reusing tie rod ends, use a proper puller rather than pickle fork to avoid boot damage.
4. 4

   Loosen outer tie rod jam nut
   Locate the jam nut (lock nut) between the inner and outer tie rod. Use 21mm wrench or adjustable wrench to loosen the jam nut completely, but do not remove it yet. The jam nut may be very tight. Hold the inner tie rod stationary if needed using tie rod pliers on the flats.
5. 5

   Remove outer tie rod end
   Count the number of turns as you unscrew the outer tie rod end from the inner tie rod. Thread it counterclockwise off the inner tie rod completely. Record the exact number of turns for each side separately. The jam nut will slide off the inner tie rod once the outer tie rod is removed.
6. 6

   Access and remove inner tie rod
   Locate where the inner tie rod connects to the steering rack. On the EDV 500, this connection is typically secured with a clamp or threaded connection. If a boot clamp is present, cut or remove the clamp securing the rack boot. Slide the boot back to expose the inner tie rod connection point at the steering rack.
7. 7

   Remove inner tie rod from steering rack
   The inner tie rod may be threaded into the rack or secured with a jam nut/clamp arrangement. Use tie rod pliers or adjustable wrench on the flats of the inner tie rod body. Unscrew counterclockwise from the rack assembly while preventing the rack from rotating. If resistance is encountered, apply additional penetrating oil and allow to soak.
8. 8

   Inspect steering rack boot and components
   With inner tie rod removed, inspect the steering rack boot for tears, cracks, or grease leakage. Check the rack threads for damage or excessive wear. Clean the rack threads with wire brush if corrosion is present. Replace rack boot if any damage is observed to prevent contamination of steering rack.
9. 9

   Install new inner tie rod
   Apply medium-strength thread locker to the threads of the new inner tie rod. Thread the new inner tie rod into the steering rack by hand first to ensure proper engagement. Tighten firmly using tie rod pliers or adjustable wrench on the flats. Without factory torque specifications, tighten firmly hand-tight plus approximately 1/4 turn, ensuring secure engagement.
10. 10

    Install rack boot and clamps
    Slide the steering rack boot back into position over the inner tie rod connection. Ensure the boot is seated properly in its groove on both the rack and inner tie rod. Install new boot clamps and tighten securely to prevent moisture and contaminant entry. Verify boot is not twisted or kinked.
11. 11

    Install jam nut and outer tie rod end
    Slide the jam nut onto the inner tie rod threads with the wide side facing the outer tie rod. Thread the new outer tie rod end onto the inner tie rod clockwise for the same number of turns counted during removal (or to match your measurement). This provides initial toe approximation. Do not tighten jam nut yet.
12. 12

    Connect outer tie rod to steering knuckle
    Insert the outer tie rod stud into the steering knuckle taper. Ensure the stud seats fully into the taper hole. Thread on the castle nut and tighten firmly hand-tight, then continue tightening. Without factory specifications, tighten until the stud taper is fully seated and the connection is firm with no play.
13. 13

    Secure castle nut and tighten jam nut
    If castle nut slots do not align with the cotter pin hole, tighten slightly more until alignment is achieved (never loosen to align). Install new cotter pin and bend ends to secure. Hold the outer tie rod end stationary and tighten the jam nut firmly against it using 21mm wrench to lock the adjustment.
14. 14

    Repeat procedure for opposite side
    Perform steps 1 through 13 on the opposite side of the vehicle, using the measurements and turn counts recorded for that specific side. Ensure both sides are completed with equal care and attention to thread engagement and initial toe settings.
15. 15

    Reinstall wheels and perform final checks
    Reinstall both front wheels and hand-thread lug nuts. Lower vehicle to ground and torque lug nuts to manufacturer specification in star pattern. Turn steering wheel lock-to-lock slowly several times to verify smooth operation and no binding. Check that tie rod boots are not twisted or damaged.

Reassembly

1. Ensure all jam nuts are tightened securely against outer tie rod ends to prevent loosening
2. Verify all cotter pins are properly installed and bent to prevent castle nut rotation
3. Confirm steering rack boots are properly seated and clamped with no tears
4. Double-check that all connections are tight with no play in any tie rod joints

Verification

• Turn steering wheel through full range of motion and verify smooth operation with no binding or unusual noises
• Grasp each front wheel at 3 and 9 o'clock positions and attempt to move side-to-side; there should be no play in tie rod connections
• Visually inspect all tie rod connections to confirm proper seating and secure fasteners
• Schedule professional four-wheel alignment immediately before driving vehicle extensively - this is mandatory for safety
• After alignment, test drive at low speed in safe area to verify proper steering response and straight-line tracking
• After first 50 miles, re-check jam nut tightness to ensure no loosening has occurred

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