This procedure covers the removal and replacement of the outer tie rod end on a 2024 Rivian EDV 500, including wheel removal, steering linkage disconnection, and alignment considerations.

Warnings

Tools required

Parts

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

Preparation

1. Park vehicle on a level, solid surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts on the affected side while vehicle is on the ground (do not remove)
4. Raise front of vehicle using floor jack at designated jacking points
5. Support vehicle securely on jack stands rated for the EDV 500's weight (approximately 5,500 lbs)
6. Remove wheel and tire assembly completely
7. Spray penetrating oil on tie rod end threads, castle nut, and steering knuckle taper (allow 10-15 minutes to penetrate)
8. Ensure steering wheel is in unlocked position for easier access

Procedure

1. 1

   Mark tie rod position
   Before loosening anything, use a white paint marker or grease pencil to mark the exact position of the outer tie rod end on the inner tie rod threads. Make a reference line across both the outer tie rod end and the inner tie rod shaft. Count and record the number of visible threads between the jam nut and the outer tie rod end. This will help maintain approximate alignment when installing the new part.
2. 2

   Remove cotter pin and castle nut
   Locate the cotter pin securing the castle nut on the outer tie rod end stud at the steering knuckle. Straighten the cotter pin ends with pliers and pull it out. If the cotter pin is corroded or difficult to remove, cut it with diagonal cutters. Once removed, use a wrench to loosen and remove the castle nut from the tie rod end stud. Do not remove the stud from the knuckle taper yet.
3. 3

   Separate tie rod end from steering knuckle
   Thread the castle nut back onto the stud by 2-3 threads to protect the threads during separation. Position the tie rod end separator tool or pickle fork between the steering knuckle and the tie rod end. Strike the tool firmly with a hammer to break the taper fit, or use a ball joint separator tool if available. The tie rod end will pop free suddenly when the taper releases. Remove the castle nut completely and pull the tie rod stud out of the knuckle.
   ⚠Wear safety glasses during this step as the tie rod may release suddenly with force.
4. 4

   Loosen jam nut
   Locate the jam nut (lock nut) on the inner tie rod where it meets the outer tie rod end. This is typically a thin nut that locks the outer tie rod in position. Use an adjustable wrench or 22mm wrench to loosen the jam nut. You may need to hold the outer tie rod end with another wrench to prevent it from spinning. Loosen the jam nut but do not remove it completely yet.
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 shaft by turning it counterclockwise. Record this number as it will help with installation. Once the outer tie rod end is free, remove the jam nut completely from the inner tie rod threads. Inspect the inner tie rod threads for damage, corrosion, or debris. Clean threads with a wire brush if necessary.
6. 6

   Prepare new outer tie rod end
   Compare the new outer tie rod end with the old one to confirm correct part. Check that the taper, stud length, and thread pitch match. Thread the jam nut onto the inner tie rod shaft first, positioning it several inches away from the end. Apply a small amount of anti-seize compound to the inner tie rod threads to prevent future seizing.
7. 7

   Install new outer tie rod end
   Thread the new outer tie rod end onto the inner tie rod shaft clockwise. Use your recorded turn count and alignment marks to position it approximately where the old tie rod was positioned. The goal is to get as close as possible to the original position. Thread it on until the alignment marks you made are approximately lined up, or until you reach the same number of turns that were required to remove the old tie rod end.
8. 8

   Install tie rod end into steering knuckle
   Insert the tie rod end stud into the steering knuckle bore. Ensure the taper is clean and free of debris. The stud should seat fully into the taper. Install the castle nut onto the stud and tighten by hand until snug. Use a torque wrench to tighten the castle nut. Since no specific torque specification is provided in the database, tighten to manufacturer specification found in the vehicle service manual (typically 35-50 ft-lbs for this application, but verify with Rivian documentation).
9. 9

   Install cotter pin
   Align the castle nut slots with the hole in the tie rod end stud. If the slots do not align with the hole, tighten the nut slightly (no more than 1/6 turn) until alignment is achieved. Never loosen the nut to align the cotter pin hole. Insert a new cotter pin through the hole and castle nut slots. Bend the cotter pin ends around the castle nut to secure it in place. Ensure the cotter pin cannot fall out.
10. 10

    Tighten jam nut
    Slide the jam nut down against the outer tie rod end body. Hold the outer tie rod end with one wrench to prevent it from turning, then tighten the jam nut securely with another wrench. Apply medium-strength thread locker to the jam nut threads if recommended by the manufacturer. This locks the outer tie rod end position and prevents it from loosening.
11. 11

    Verify installation
    Visually inspect all connections to ensure the tie rod end is fully seated in the steering knuckle taper, the castle nut is tight, and the cotter pin is properly installed. Check that the jam nut is tight against the outer tie rod end. Grasp the tire at 3 and 9 o'clock positions and attempt to move it side to side to check for any play in the tie rod connection. There should be no looseness.

Reassembly

1. Reinstall wheel and tire assembly, threading lug nuts by hand first
2. Lower vehicle partially so tire contacts ground but vehicle weight is still on jack stands
3. Tighten lug nuts in a star pattern to manufacturer specification (typically 130-150 ft-lbs for EDV 500)
4. Remove jack stands and lower vehicle completely to the ground
5. Perform final lug nut torque check with vehicle on ground
6. Test steering by turning wheel lock-to-lock while stationary to ensure full range of motion without binding

Verification

• Start vehicle and verify electric power steering system operates normally with no warning lights
• Perform a slow-speed test drive in a safe area, checking for unusual steering feel, pulling, or noise
• Verify steering returns to center smoothly after turns
• Check for any vibration or shimmy at low speeds that would indicate improper installation
• Schedule a professional wheel alignment immediately, as the toe setting will be incorrect after tie rod replacement
• After alignment, verify tire wear pattern returns to normal over the next few hundred miles

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