This procedure covers the removal and replacement of the outer tie rod end on a 2025 Rivian EDV 500, including steering linkage disconnection, alignment marking, and post-installation verification.

Warnings

Tools required

Parts

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

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels to prevent vehicle movement
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack and support securely on jack stands under manufacturer-recommended lift points
5. Remove wheel completely and set aside
6. Spray penetrating oil on tie rod threads, jam nut, and castle nut if corrosion is present (allow 10-15 minutes to penetrate)

Procedure

1. 1

   Mark alignment reference points
   Using a white paint pen or marker, mark the position of the outer tie rod end on the inner tie rod threads. Make a clear line across both the outer tie rod end body and the inner tie rod shaft. Additionally, count and record the number of exposed threads visible beyond the outer tie rod end. Take photos from multiple angles for reference.
2. 2

   Measure tie rod length
   Measure the overall length from the center of the inner tie rod end ball joint to the center of the outer tie rod end ball joint. Record this measurement to within 1/8 inch accuracy. This will serve as a backup reference for installation.
3. 3

   Remove cotter pin and castle nut
   Straighten and remove the cotter pin from the outer tie rod end castle nut using pliers. Discard the old cotter pin. Using a 21mm socket, remove the castle nut from the outer tie rod end stud. Do not reuse the castle nut if specified as single-use by manufacturer.
4. 4

   Separate tie rod end from knuckle
   Position the tie rod end separator tool between the steering knuckle and the tie rod end. Tighten the tool gradually to apply pressure, or strike the tool sharply if using a pickle fork style. Alternatively, support the steering knuckle and strike the knuckle boss with a rubber mallet while applying upward pressure on the tie rod end. The taper will release and the tie rod stud will separate from the knuckle.
5. 5

   Loosen jam nut
   Locate the jam nut (lock nut) that secures the outer tie rod end to the inner tie rod. Using a 19mm wrench, loosen but do not remove the jam nut. Move it back toward the inner tie rod end to expose the threads.
6. 6

   Remove outer tie rod end
   Grip the outer tie rod end body with an adjustable wrench or locking pliers. While holding the inner tie rod steady, unthread the outer tie rod end by rotating counterclockwise. Count the number of complete rotations required for removal and record this number. Remove the jam nut from the inner tie rod threads.
7. 7

   Inspect and clean threads
   Inspect the inner tie rod threads for damage, corrosion, or stripped threads. Clean threads thoroughly with a wire brush. Check the inner tie rod boot for tears or damage. If the boot is damaged, it must be replaced to prevent contamination of the steering rack.
8. 8

   Install new jam nut
   Thread the jam nut onto the inner tie rod with the thinner side facing outward toward where the outer tie rod end will be installed. This ensures proper locking action when tightened.
9. 9

   Thread new outer tie rod end
   Apply a small amount of medium-strength thread locker to the first few threads of the inner tie rod if recommended by manufacturer. Thread the new outer tie rod end clockwise onto the inner tie rod. Thread it on the same number of turns recorded during removal, or align with the paint mark made earlier. Verify the overall length matches your recorded measurement.
10. 10

    Install tie rod end into knuckle
    Insert the outer tie rod end stud into the steering knuckle taper. Ensure the stud seats fully into the taper. Install the new castle nut and tighten by hand until snug. The tie rod end should not rotate freely at this point.
11. 11

    Torque castle nut and install cotter pin
    Using a torque wrench with 21mm socket, tighten the castle nut to manufacturer specification. Note: Specific torque value not available in database - consult service manual for 2025 Rivian EDV 500 specification (typically 35-50 ft-lbs for similar vehicles). If the cotter pin holes do not align, tighten the nut further until the next slot aligns - never loosen to align. Install a new cotter pin through the castle nut and stud, then bend the ends to secure.
12. 12

    Tighten jam nut
    Hold the outer tie rod end body with an adjustable wrench to prevent rotation. Using a 19mm wrench, tighten the jam nut against the outer tie rod end body securely. Note: Specific torque value not available in database - consult service manual for 2025 Rivian EDV 500 specification (typically 35-55 ft-lbs for similar vehicles).
13. 13

    Verify installation and range of motion
    Verify the tie rod end is fully seated in the knuckle taper and all fasteners are secure. Rotate the steering wheel lock-to-lock while observing the tie rod end for proper movement, binding, or unusual play. Check that the tie rod end boot is properly seated and not twisted.

Reassembly

1. Reinstall wheel and hand-tighten lug nuts in a star pattern
2. Lower vehicle until tire just contacts ground but weight is still on jack stands
3. Torque wheel lug nuts to manufacturer specification in a star pattern (consult service manual for 2025 Rivian EDV 500 specification)
4. Fully lower vehicle and remove jack stands
5. Perform final torque verification on wheel lug nuts with vehicle on ground

Verification

• Test drive vehicle in a safe area at low speed to verify steering response and feel
• Listen for any unusual noises from the steering system during turns
• Verify no pulling to either side during straight-line driving (though some deviation is expected until alignment is performed)
• Schedule a professional four-wheel alignment as soon as possible, as the toe setting will be incorrect
• After alignment, re-verify that jam nut remains tight and cotter pin is secure

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