Tie Rod Assembly

This procedure covers the removal and replacement of the tie rod assembly on a 2025 Rivian EDV 500, including outer tie rod end and inner tie rod replacement, requiring front end alignment upon completion.

Warnings

Tools required

Parts

• Tie rod assembly (inner and outer) × 1 — Use OEM specification
• Outer tie rod end castle nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification
• Inner tie rod boot/bellows × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Power off the vehicle completely using the center screen and remove key fob from vehicle interior
4. Wait at least 5 minutes for high-voltage system capacitors to discharge
5. Loosen front wheel lug nuts while vehicle is still on ground (do not remove)
6. Raise front of vehicle with floor jack at designated lift points and support with jack stands rated for at least 3 tons each
7. Remove front wheel on side requiring tie rod replacement
8. Spray all tie rod fasteners and tapers with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Measure and mark existing tie rod position
   Before removing any components, measure the distance from the inner tie rod jam nut to the end of the outer tie rod threads. Record this measurement. Use a marking pen to mark the position of the jam nut on the threads relative to the outer tie rod. This will help maintain approximate toe alignment during installation.
2. 2

   Remove outer tie rod end cotter pin and castle nut
   Locate the outer tie rod end where it connects to the steering knuckle. Straighten and remove the cotter pin from the castle nut. Remove the castle nut from the tie rod end stud. Note: Do not fully remove the nut initially; loosen it but leave it threaded on a few turns to protect threads during separation.
3. 3

   Separate outer tie rod end from steering knuckle
   Using a tie rod separator tool or pickle fork, separate the outer tie rod end taper from the steering knuckle. Insert the separator between the knuckle and tie rod end and strike with a hammer or use the forcing screw depending on tool type. Once taper is broken free, remove the castle nut completely and pull the tie rod end out of the knuckle.
   ⚠A pickle fork will damage the tie rod end boot and may damage the knuckle if used improperly. Use a proper tie rod separator or ball joint puller whenever possible.
4. 4

   Loosen jam nut and remove outer tie rod end
   Locate the jam nut that secures the outer tie rod end to the inner tie rod. Use an adjustable wrench or appropriate size wrench to loosen the jam nut. Count and record the number of turns required to remove the outer tie rod end from the inner tie rod threads. Remove the outer tie rod end completely.
5. 5

   Remove inner tie rod boot clamps
   Locate the inner tie rod boot (bellows) that covers the connection between the inner tie rod and the steering rack. Cut or remove the boot clamps securing the boot to the steering rack and tie rod. Slide the boot back to expose the inner tie rod connection.
6. 6

   Remove inner tie rod from steering rack
   Using an inner tie rod removal tool that matches the flat surfaces of the inner tie rod, secure the tool onto the inner tie rod. Hold the steering rack steady with a wrench on the rack housing flats if accessible. Turn the inner tie rod counterclockwise to unthread it from the steering rack. The inner tie rod may require significant force to break loose initially.
   ⚠Do not use pliers or adjustable wrenches directly on the inner tie rod threads as this will damage the threads. Use the proper inner tie rod removal tool.
7. 7

   Inspect steering rack threads and clean
   With the inner tie rod removed, inspect the threads inside the steering rack for damage, debris, or corrosion. Use a wire brush to clean the threads if necessary. Check that the threads are not stripped or cross-threaded.
8. 8

   Install new inner tie rod
   Thread the new inner tie rod into the steering rack by hand, turning clockwise. Ensure it threads smoothly without cross-threading. Once hand-tight, use the inner tie rod removal tool to tighten the inner tie rod fully. Note: Without manufacturer torque specifications, tighten firmly until seated, typically requiring significant force with a long-handled tool.
   ℹ️Manufacturer torque specifications are not available in the database. Tighten the inner tie rod firmly using proper tooling until fully seated against the rack housing.
9. 9

   Install new inner tie rod boot
   Slide the new inner tie rod boot over the inner tie rod and position it correctly over the steering rack housing and tie rod. Secure the boot with new clamps at both ends, ensuring the boot is not twisted and is properly seated to prevent contamination of the steering rack.
10. 10

    Install outer tie rod end to approximate position
    Thread the outer tie rod end onto the inner tie rod threads, using your previous measurements and marks as a guide. Thread it on the same number of turns you recorded during removal. Position the jam nut to the marked location. This provides an approximate alignment to allow the vehicle to be driven to an alignment shop.
11. 11

    Connect outer tie rod end to steering knuckle
    Insert the outer tie rod end stud into the steering knuckle taper. Install the new castle nut and tighten until snug. Note: Without manufacturer specifications, tighten the castle nut until it seats firmly and the cotter pin holes align. If holes do not align, tighten further until the next castle slot aligns with the hole.
    ⚠Never loosen the castle nut to align the cotter pin hole. Only tighten to the next available slot.
12. 12

    Install new cotter pin
    Insert a new cotter pin through the castle nut and tie rod stud. Bend the ends of the cotter pin in opposite directions to secure it in place. Ensure the cotter pin is fully seated and cannot come loose.
13. 13

    Tighten jam nut
    Hold the outer tie rod end with one wrench to prevent it from turning. Use another wrench to tighten the jam nut securely against the outer tie rod end. This locks the two components together and prevents the outer tie rod from threading in or out during operation.

Reassembly

1. Reinstall the front wheel and hand-tighten lug nuts in a star pattern
2. Lower vehicle until tire just touches the ground but vehicle weight is still on jack stands
3. Torque wheel lug nuts to manufacturer specification in a star pattern (typically 130-140 ft-lb for Rivian, verify in owner's manual)
4. Fully lower vehicle and remove jack stands
5. Remove wheel chocks

Verification

• Start the vehicle and verify the electric power steering system initializes without warning lights on the dashboard
• Turn the steering wheel lock-to-lock while stationary and verify smooth operation with no binding or unusual noises
• Visually inspect all tie rod connections to ensure proper installation and no loose fasteners
• Test drive vehicle at low speed in a safe area to verify basic steering function
• Schedule a professional front-end alignment immediately, as toe adjustment is required after tie rod replacement
• After alignment, verify steering wheel is centered when driving straight and vehicle does not pull to one side

More procedures for this vehicle