This procedure covers the removal and replacement of both inner and outer tie rod ends on the front suspension of a 2024 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Outer tie rod end - driver side × 1 — Use OEM specification
• Outer tie rod end - passenger side × 1 — Use OEM specification
• Inner tie rod end - driver side × 1 — Use OEM specification
• Inner tie rod end - passenger side × 1 — Use OEM specification
• Tie rod end castle nuts × 4 — Use OEM specification
• Cotter pins × 4 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is still on ground (do not remove)
4. Raise front of vehicle using floor jack at designated front lift points
5. Support vehicle securely on jack stands rated for at least 4 tons each
6. Remove both front wheels completely
7. Spray penetrating oil on all tie rod connections and allow to soak for 10-15 minutes

Procedure

1. 1

   Mark existing tie rod positions
   Before loosening anything, use white paint marker or tape to mark the exact position of each outer tie rod end where it threads onto the inner tie rod. Count and record the number of visible threads on each side. Measure and record the overall length from the center of the inner tie rod ball joint to the center of the outer tie rod ball joint on both sides. This preserves approximate alignment settings.
2. 2

   Remove outer tie rod end castle nuts
   Locate the castle nut securing each outer tie rod end to the steering knuckle. Remove the cotter pin from each castle nut using pliers. Using a 21mm socket, loosen and remove the castle nut from the outer tie rod ball joint stud on both sides. Do not discard the nuts if they are in good condition and will be reused.
3. 3

   Separate outer tie rod ends from steering knuckles
   Using a tie rod end separator tool or pickle fork, carefully separate the outer tie rod ball joint stud from the steering knuckle on both sides. Position the separator between the tie rod end and knuckle, then strike with a hammer or use the threaded press action to pop the taper free. Avoid damaging the steering knuckle or ball joint boot.
   ⚠Pickle fork tools will damage the tie rod boot. Only use if replacing the tie rod end. Use a ball joint separator press tool to preserve components.
4. 4

   Remove outer tie rod ends
   Hold the inner tie rod firmly with an adjustable wrench on the flat surfaces to prevent it from rotating. Using another wrench, unthread the outer tie rod end counter-clockwise. Count the exact number of turns required to remove each outer tie rod end and record this information for installation reference. Remove outer tie rods from both sides.
5. 5

   Access inner tie rod ends
   Inspect the steering rack boot on each side where the inner tie rod connects. The inner tie rod is typically secured with a pinch bolt or crimped boot clamp. Pull back or loosen the boot clamp on each side to expose the inner tie rod connection to the steering rack. On the EDV 500, the inner tie rod may have a threaded connection or a staked/crimped connection.
6. 6

   Remove inner tie rod ends
   If the inner tie rod has a threaded connection, use a large adjustable wrench or inner tie rod removal tool to unthread it from the steering rack (typically 32-36mm). If the inner tie rod is staked or crimped, use a ball joint press or inner tie rod removal tool to break the stake and extract the tie rod. Remove inner tie rods from both sides. Clean the steering rack threads with a wire brush.
   ⚠Do not allow the steering rack to rotate excessively during inner tie rod removal, as this can damage the steering angle sensor or rack internals.
7. 7

   Install new inner tie rod ends
   Apply a small amount of thread locking compound to the threads of the new inner tie rod ends. Thread the new inner tie rods into the steering rack by hand first to ensure proper thread engagement. Tighten the inner tie rod ends using the appropriate tool. If threaded type, tighten to manufacturer specification (typically 55-75 ft-lbs for this class of vehicle, but verify with OEM documentation). If staked type, ensure proper seating and apply new stake or crimp as specified.
   ℹ️Without manufacturer torque specifications in database, consult Rivian service documentation or OEM installation instructions included with replacement parts for exact torque values.
8. 8

   Reinstall steering rack boots
   Slide the steering rack boots back into position over the inner tie rod connection points on both sides. Secure the boots with new clamps, ensuring they are properly seated in the groove and not twisted. The boots must be airtight to prevent contamination of the steering rack.
9. 9

   Install new outer tie rod ends
   Thread the new outer tie rod ends onto the inner tie rods, aligning with the reference marks made during disassembly. Turn each outer tie rod end the same number of turns that were counted during removal. Verify that the overall tie rod length matches the measurements recorded earlier. This provides a starting point for alignment.
10. 10

    Connect outer tie rod ends to steering knuckles
    Insert the outer tie rod ball joint stud into the steering knuckle hole on both sides. Install the castle nuts and tighten them to the appropriate specification (typically 35-50 ft-lbs for this application, but verify with OEM documentation). Ensure the castle nut slots align with the cotter pin hole in the stud. If necessary, tighten slightly further to achieve alignment, never loosen.
11. 11

    Install new cotter pins
    Insert new cotter pins through the castle nut slots and the ball joint stud holes on all four tie rod connections. Bend the cotter pin legs in opposite directions to secure them properly. Ensure cotter pins are fully seated and cannot back out.
12. 12

    Verify steering operation
    With the vehicle still raised on jack stands, turn the steering wheel slowly from lock to lock several times. Verify that all tie rod connections are secure with no looseness or binding. Check that the steering wheel returns to center smoothly. Inspect all connections for proper installation and ensure no components contact suspension or brake parts throughout the steering range.

Reassembly

1. Reinstall both front wheels and hand-tighten lug nuts in a star pattern
2. Lower vehicle to the ground carefully
3. Torque wheel lug nuts to manufacturer specification (typically 150 ft-lbs for EDV 500) in a star pattern
4. Perform a final visual inspection of all tie rod connections and ensure cotter pins are secure

Verification

• Start the vehicle and turn the steering wheel slowly through full range of motion while stationary
• Check for any unusual noises, binding, or resistance in the steering system
• Drive the vehicle at low speed in a safe area and verify steering response is predictable
• Schedule a professional wheel alignment immediately - vehicle will likely pull to one side and have incorrect toe settings
• After alignment, verify steering wheel is centered and vehicle tracks straight with no pull
• Re-inspect all tie rod connections after 50-100 miles of driving to ensure no looseness has developed

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