Steering Shaft - Upper

This procedure covers the removal and replacement of the upper steering shaft on a 2025 Rivian EDV 500 commercial delivery van, including disconnection from the steering column and intermediate shaft.

Warnings

Tools required

Parts

• Upper steering shaft assembly × 1 — Use OEM specification
• Steering shaft coupling bolt × 1 — Use OEM specification
• Pinch bolt (if reusable bolt not specified) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure front wheels are pointed straight ahead
3. Disconnect 12V battery negative terminal and wait at least 2 minutes for airbag system capacitors to discharge
4. Remove driver's side lower dashboard panel and knee bolster for access to steering column
5. Tape or secure the steering wheel in the centered position to prevent rotation

Procedure

1. 1

   Mark shaft alignment
   Using the white paint marker, mark the alignment relationship between the upper steering shaft and the intermediate shaft coupling, and between the upper shaft and the steering column. Make clear reference marks on both mating components at each connection point to ensure proper alignment during reassembly.
2. 2

   Remove lower dashboard trim
   Remove any remaining trim panels or covers that obstruct access to the upper steering shaft and column area. On the EDV 500, this typically includes the driver's side lower dash panel and any wire harness clips attached to the column shroud. Set aside trim panels in a clean area to prevent damage.
3. 3

   Disconnect electrical connectors
   Locate and disconnect all electrical connectors attached to the steering column assembly, including the steering angle sensor connector and any column control module connectors. Press the locking tabs and carefully pull connectors straight off to avoid damaging pins. Note the routing and position of wiring harnesses for reassembly.
4. 4

   Remove intermediate shaft coupling bolt
   Locate the pinch bolt or coupling bolt that secures the upper steering shaft to the intermediate shaft below the dash. Apply penetrating oil if necessary. Remove the coupling bolt completely. Note whether the bolt is a single-use type that requires replacement.
5. 5

   Separate intermediate shaft connection
   With the coupling bolt removed, carefully separate the upper steering shaft from the intermediate shaft splines. You may need to use a small pry bar or apply gentle tapping to break the connection. Be careful not to damage the splines or allow the intermediate shaft to drop or rotate.
6. 6

   Remove steering column mounting bolts
   Locate the bolts securing the steering column assembly to the dashboard support structure. On the Rivian EDV 500, there are typically 3-4 mounting bolts. Support the column assembly with one hand while removing the bolts to prevent the column from dropping. Remove bolts in a star pattern if applicable.
7. 7

   Lower steering column assembly
   Carefully lower the steering column assembly enough to access the upper steering shaft attachment points. Support the column weight to prevent stress on any remaining electrical connections. Do not allow the steering wheel to turn during this process.
8. 8

   Remove upper shaft retaining mechanism
   Identify and remove any retaining clips, roll pins, or fasteners that secure the upper steering shaft to the steering column. This may include a roll pin through the shaft, a pinch bolt, or a splined connection with a retaining mechanism. Use appropriate tools to avoid damaging the column housing.
9. 9

   Extract upper steering shaft
   Slide the upper steering shaft out of the steering column assembly. Note the orientation and any alignment features such as spline indexing or flat spots. Inspect the column bearings and bushings for wear or damage while the shaft is removed.
10. 10

    Install new upper steering shaft
    Insert the new upper steering shaft into the steering column, aligning any splines or keyed features according to your alignment marks. Ensure the shaft slides smoothly without binding. Verify that the shaft is fully seated in the column before securing.
11. 11

    Secure upper shaft to column
    Install and secure the upper shaft retaining mechanism (roll pin, pinch bolt, or clips) according to manufacturer specifications. Verify the shaft is properly retained and cannot slide out of the column assembly. Check for smooth rotation of the shaft within the column.
12. 12

    Reinstall steering column mounting
    Raise the steering column assembly back into position against the dashboard support structure. Align the mounting holes and install the column mounting bolts. Tighten bolts in a star pattern to proper specification (refer to manufacturer documentation as no torque values are currently in database).
13. 13

    Connect intermediate shaft
    Align the upper steering shaft with the intermediate shaft using the alignment marks made during disassembly. Ensure the splines fully engage and both shafts are properly indexed. Install the new coupling bolt and tighten to proper specification (refer to manufacturer documentation).
14. 14

    Reconnect electrical connections
    Reconnect all electrical connectors to the steering column assembly, including the steering angle sensor and column control modules. Ensure all connectors click fully into place and locking tabs are engaged. Route wiring harnesses according to original positions.

Reassembly

1. Reinstall all dashboard trim panels and knee bolster, ensuring all clips and fasteners are properly secured
2. Remove steering wheel securing tape
3. Reconnect 12V battery negative terminal
4. Start vehicle and verify no warning lights related to steering or airbag systems appear
5. Perform steering angle sensor calibration procedure using Rivian diagnostic software if available

Verification

• Turn steering wheel lock-to-lock while stationary to verify smooth operation with no binding or unusual noises
• Verify steering wheel is properly centered when front wheels are straight ahead
• Check for any unusual play or looseness in the steering system
• Perform a low-speed test drive to verify proper steering feel and responsiveness
• Confirm no warning lights are illuminated on the instrument cluster
• Verify all electrical functions on the steering column operate correctly (turn signals, cruise control, etc.)

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