This procedure covers the removal and replacement of the intermediate steering shaft on a 2024 Rivian EDV 500 commercial delivery van, connecting the steering column to the steering rack.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM Rivian part
• Steering shaft pinch bolt (upper) × 1 — Use OEM specification
• Steering shaft pinch bolt (lower) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure front wheels are in straight-ahead position
3. Disconnect 12V auxiliary battery (located in front compartment) and wait 2 minutes for system discharge
4. Raise and safely support front of vehicle on jack stands
5. Remove front driver side wheel for improved access to lower shaft area
6. Remove lower dash panel and driver side knee bolster for access to upper steering column area
7. Lock steering wheel in center position using steering wheel holder to prevent rotation

Procedure

1. 1

   Mark alignment positions
   Using a paint marker, make alignment marks across both upper and lower U-joint couplings where the intermediate shaft connects to the steering column and steering rack. Make marks on the shaft and both mating components. Take photos for reference during reassembly.
2. 2

   Access upper steering shaft connection
   Working from inside the cab, locate the upper pinch bolt where the intermediate shaft connects to the steering column shaft below the instrument panel. Clean any debris from the bolt and surrounding area with a wire brush. Apply penetrating lubricant if corrosion is present.
3. 3

   Remove upper pinch bolt
   Remove the upper steering shaft pinch bolt using a Torx or metric socket as applicable. Note the bolt orientation and whether a tab washer is present. Do not allow the intermediate shaft to rotate during removal. Support the shaft to prevent it from dropping.
4. 4

   Access lower steering shaft connection
   Working from underneath the vehicle in the wheel well area, locate the lower pinch bolt where the intermediate shaft connects to the steering rack input shaft. Clean the area thoroughly. You may need to position yourself to look upward into the frame area where the steering rack is mounted.
5. 5

   Remove lower pinch bolt
   Remove the lower steering shaft pinch bolt securing the intermediate shaft to the steering rack input shaft. Keep track of any washers or spacers. Support the intermediate shaft as the final fastener is removed.
6. 6

   Separate upper connection
   Working from inside the cab, carefully pull the upper portion of the intermediate shaft away from the steering column splines. You may need to gently tap the yoke with a rubber mallet or use a small pry bar to break the connection. Avoid using excessive force that could damage splines.
7. 7

   Separate lower connection and remove shaft
   Working from underneath, separate the lower U-joint from the steering rack input shaft. Maneuver the intermediate shaft assembly through the firewall pass-through opening. Note the routing path and any clips or guides that position the shaft during removal.
8. 8

   Inspect components
   Inspect the steering column splines, steering rack input shaft splines, and all U-joint components for wear, damage, or corrosion. Check that the steering wheel has not rotated from center position. Inspect the firewall boot for tears or deterioration. Replace any damaged components.
9. 9

   Prepare new intermediate shaft
   Unpack the new intermediate shaft assembly. Verify it matches the old part. If the shaft has a collapsible section, ensure it is not compressed. Apply a light coating of clean grease to the upper and lower splines to facilitate installation.
10. 10

    Install intermediate shaft
    Route the new intermediate shaft through the firewall opening following the same path as the original. Position any routing clips or guides. Align the lower U-joint with the steering rack input shaft, matching your alignment marks. Slide the lower connection together ensuring proper spline engagement.
11. 11

    Install lower pinch bolt
    Install the new lower pinch bolt with any washers in their original orientation. Verify alignment marks match. Tighten the bolt by hand first to ensure proper threading, then torque to specification using a torque wrench. Since no torque spec is provided in the database, follow Rivian service manual specifications exactly.
12. 12

    Connect upper shaft
    Working from inside the cab, align the upper U-joint with the steering column shaft, matching your alignment marks. Slide the connection together ensuring full spline engagement. The shaft should slide on smoothly without forcing.
13. 13

    Install upper pinch bolt
    Install the new upper pinch bolt with correct orientation. Verify alignment marks are matched. Hand-tighten first, then torque to Rivian specification. Ensure the bolt fully clamps the joint without gaps.

Reassembly

1. Reinstall driver side knee bolster and lower dash panel
2. Reinstall driver side front wheel and torque lug nuts to specification
3. Lower vehicle from jack stands
4. Remove steering wheel lock
5. Reconnect 12V auxiliary battery

Verification

• With vehicle still parked and off, verify steering wheel turns smoothly lock-to-lock without binding or unusual resistance
• Check that steering wheel is centered with wheels pointed straight ahead
• Start vehicle and verify no warning lights related to steering or power steering systems
• Perform a slow-speed steering test in a safe area, verifying smooth operation and proper wheel return to center
• Test drive vehicle at various speeds and verify normal steering feel, no vibration, clunking, or binding
• Verify no abnormal noises from steering column or shaft during full lock turns
• Confirm steering wheel position sensor has not triggered any fault codes by checking vehicle diagnostics if available

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