Tie Rod End - Inner

This procedure covers the removal and replacement of the inner tie rod end on a 2025 Rivian EDV 500 dual motor electric delivery van, requiring front suspension disassembly and wheel alignment afterward.

Warnings

Tools required

Parts

• Inner tie rod end × 1 — Use OEM Rivian specification
• Tie rod boot kit (if damaged) × 1 — Use OEM specification
• Cotter pin (if equipped) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Power down the vehicle completely using the main power-off procedure
4. Disconnect the 12V battery negative terminal and wait 5 minutes for system discharge
5. Loosen front wheel lug nuts while vehicle is on the ground
6. Raise front of vehicle and secure on jack stands at manufacturer-specified lift points
7. Remove front wheel on the side requiring service
8. Spray penetrating oil on all tie rod connections and allow to soak for 10-15 minutes

Procedure

1. 1

   Mark and measure tie rod position
   Before disassembly, measure and mark the exact position of the outer tie rod end relative to the inner tie rod end. Use a tape measure to record the distance from the inner tie rod housing to the outer tie rod end jam nut. Take a photo for reference. Mark the threaded section with paint or marker to indicate the current position. This is critical for maintaining approximate alignment during reassembly.
2. 2

   Remove outer tie rod end from knuckle
   Remove the cotter pin (if equipped) from the outer tie rod end castle nut. Remove the castle nut from the outer tie rod stud. Use a tie rod separator tool or pickle fork to separate the outer tie rod end from the steering knuckle. Do not strike the steering knuckle directly to avoid damage to the ball joint or knuckle. Once separated, support the tie rod assembly to prevent strain on the steering rack boot.
3. 3

   Loosen jam nut
   Using an appropriate wrench, loosen the jam nut that secures the outer tie rod end to the inner tie rod. Do not remove it completely yet. This jam nut locks the adjustment position and must be loosened before the outer tie rod can be removed from the inner tie rod.
4. 4

   Remove outer tie rod from inner tie rod
   Count and record the exact number of turns as you unthread the outer tie rod end from the inner tie rod. This serves as a backup measurement for reassembly. Remove the outer tie rod end completely and set aside. Remove the jam nut from the inner tie rod threads.
5. 5

   Access inner tie rod connection
   Inspect the steering rack boot at the inner tie rod connection point. Carefully pull back or remove the boot clamps to expose the inner tie rod connection to the steering rack. On the Rivian EDV 500, the boot may be secured with spring clamps or screw-type clamps. Be careful not to tear the boot material. If the boot is damaged, it must be replaced.
6. 6

   Remove inner tie rod end
   Use an inner tie rod removal tool (crow's foot style wrench or specialized tie rod tool) to grip the flat surfaces of the inner tie rod body. The inner tie rod typically threads directly into the steering rack or is secured with a staked crimped connection. Unthread the inner tie rod counterclockwise while preventing the steering rack from rotating. If the connection is staked, the stake may need to be ground or filed down before removal is possible. Apply steady pressure to break the connection loose.
7. 7

   Clean steering rack threads
   Once the old inner tie rod is removed, inspect the steering rack threads for damage or debris. Use a wire brush to clean the threads thoroughly. Check for any metal shavings or contamination inside the steering rack boot area. Wipe clean with a lint-free cloth. Inspect the rack for any signs of fluid leakage or damage.
8. 8

   Install new inner tie rod end
   Apply a small amount of medium-strength thread locker to the steering rack threads (if recommended by manufacturer). Thread the new inner tie rod end into the steering rack by hand to ensure proper thread engagement. Once hand-tight, use the inner tie rod tool to tighten the inner tie rod. Without published torque specifications, tighten to a firm, secure position comparable to the original installation. Note that some inner tie rod ends may require staking or crimping after installation per manufacturer specifications.
9. 9

   Install and adjust outer tie rod end
   Thread the jam nut onto the inner tie rod threads first. Thread the outer tie rod end onto the inner tie rod, using your recorded turn count and reference marks to achieve approximately the same position as before removal. This will get the alignment close enough for driving to an alignment shop. Do not fully tighten the jam nut yet.
10. 10

    Connect outer tie rod to steering knuckle
    Insert the outer tie rod end stud into the steering knuckle. Install the castle nut and tighten to the appropriate torque specification (consult Rivian service documentation as no specification is available in this database). Align the castle nut slots with the stud hole and install a new cotter pin. Bend the cotter pin ends to secure.
11. 11

    Reinstall steering rack boot
    Reposition the steering rack boot over the inner tie rod connection, ensuring it is properly seated in both grooves (rack housing and inner tie rod). Install new boot clamps and tighten securely. Ensure the boot is not twisted and has adequate clearance for full steering travel. Check that no folds or tears are present in the boot material.
12. 12

    Perform preliminary inspection
    Before reinstalling the wheel, manually rotate the steering wheel lock-to-lock slowly while observing the tie rod assembly for proper movement, binding, or interference. Check that all connections are secure and that the steering rack boot moves freely without restriction. Verify all fasteners are properly installed.

Reassembly

1. Reinstall the front wheel and hand-tighten lug nuts in a star pattern
2. Lower vehicle to the ground and torque wheel lug nuts to specification in a star pattern
3. Reconnect the 12V battery negative terminal
4. Power on the vehicle and verify no warning lights related to steering or suspension systems
5. Tighten the tie rod jam nut against the outer tie rod end to lock the adjustment (without published torque specs, tighten firmly to prevent movement)

Verification

• Test drive the vehicle at low speed in a safe area to verify steering function and that the vehicle tracks reasonably straight
• Listen for any unusual noises from the front suspension during turning and straight-line driving
• Schedule a professional four-wheel alignment immediately after this repair, as proper alignment is critical for safety and tire wear
• After alignment, verify steering wheel is centered and vehicle tracks straight without pulling
• Recheck all fasteners including tie rod connections and wheel lug nuts after 50-100 miles of driving

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