This procedure covers the removal and replacement of both inner and outer tie rod ends on the 2025 Rivian EDV 500, including alignment considerations for the electric delivery van platform.

Warnings

Tools required

Parts

• Outer tie rod end - Driver side × 1 — Use OEM Rivian specification
• Outer tie rod end - Passenger side × 1 — Use OEM Rivian specification
• Inner tie rod end - Driver side × 1 — Use OEM Rivian specification
• Inner tie rod end - Passenger side × 1 — Use OEM Rivian specification
• Tie rod jam nut (if not included with tie rod) × 4 — Use OEM Rivian specification
• Cotter pins × 4 — Various sizes as required

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Turn ignition to OFF position and remove key fob from vehicle interior
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Raise front of vehicle using floor jack at designated lift points
6. Support vehicle with jack stands rated for at least 4 tons each on manufacturer-specified frame points
7. Remove front wheels completely
8. Spray all tie rod end nuts, jam nuts, and steering rack boots with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Mark and measure existing tie rod position
   Before removing any components, use a paint marker to mark the exact position where the outer tie rod threads into the inner tie rod on both sides. Additionally, measure the total length from the center of the inner tie rod to the center of the outer tie rod ball joint. Record these measurements for both driver and passenger sides to aid in approximate reinstallation alignment.
2. 2

   Remove outer tie rod end castle nuts
   Locate the outer tie rod end at the steering knuckle connection. Remove and discard the cotter pin from the castle nut. Using a 19mm wrench or socket, loosen and remove the castle nut from the outer tie rod ball stud. Do not remove the outer tie rod from the knuckle yet.
3. 3

   Separate outer tie rod from steering knuckle
   Using a tie rod separator tool or pickle fork, separate the outer tie rod ball joint from the steering knuckle. Position the separator between the knuckle and tie rod end, then apply pressure using a hammer or press until the taper releases. The EDV 500 uses a standard taper fit design. Avoid damaging the steering knuckle surface or CV boot during separation.
4. 4

   Remove outer tie rod from inner tie rod
   Locate the jam nut between the inner and outer tie rod ends. Using a 21mm wrench, loosen the jam nut. Once loose, thread the outer tie rod end off the inner tie rod by turning counterclockwise. Count the number of turns required for complete removal and record this for reinstallation reference. Remove the jam nut completely.
5. 5

   Access and remove steering rack bellows boot
   Locate the rubber accordion-style bellows boot that covers the inner tie rod connection to the steering rack. Remove the clamps securing the boot to both the steering rack housing and the inner tie rod using pliers or a clamp removal tool. Slide the boot toward the center of the vehicle to expose the inner tie rod connection point and flat sections.
6. 6

   Remove inner tie rod end
   The inner tie rod on the EDV 500 typically has flats machined into the rod body near the steering rack connection. Using adjustable pliers or a specialized inner tie rod tool, grip these flats firmly. Turn counterclockwise to unthread the inner tie rod from the steering rack. If the rack begins to rotate, have an assistant hold the opposite side or use a rack holding tool. Remove the inner tie rod completely.
7. 7

   Inspect steering rack and clean threads
   With the inner tie rod removed, visually inspect the steering rack threads for damage, cross-threading, or excessive wear. Check for any fluid leakage from the rack housing which would indicate seal failure. Use a wire brush to clean the rack threads thoroughly, removing any corrosion or debris. Inspect the bellows boot for tears or damage and replace if necessary.
8. 8

   Install new inner tie rod end
   Apply a light coat of anti-seize compound to the first few threads of the new inner tie rod. Thread the inner tie rod into the steering rack by hand, ensuring it starts straight and does not cross-thread. Once hand-tight, use the adjustable pliers or inner tie rod tool on the flats to tighten the inner tie rod fully. Although specific torque specs are not available, tighten firmly to manufacturer specification if available, typically in the 55-75 ft-lbs range for similar vehicles.
9. 9

   Reinstall steering rack bellows boot
   Slide the bellows boot back over the inner tie rod connection, ensuring it seats properly in the groove on both the rack housing and the inner tie rod body. Install new clamps and tighten securely to prevent water and debris intrusion. Ensure the boot is not twisted or pinched.
10. 10

    Install new outer tie rod end
    Thread the jam nut onto the new inner tie rod first, then thread the new outer tie rod end onto the inner tie rod. Using your reference marks and turn count from removal, thread the outer tie rod to approximately the same position as the original. Do not tighten the jam nut yet. The goal is to get close to the original alignment to minimize post-repair alignment adjustment.
11. 11

    Connect outer tie rod to steering knuckle
    Insert the outer tie rod ball stud into the steering knuckle taper. Thread the new castle nut onto the ball stud and tighten using a torque wrench. Although specific torque is not listed in the database, typical specification is 35-50 ft-lbs for this application. Tighten until the next castle nut slot aligns with the ball stud hole, then insert a new cotter pin and bend the legs to secure.
12. 12

    Tighten tie rod jam nut
    While holding the outer tie rod end to prevent rotation, tighten the jam nut using a 21mm wrench. The jam nut should be tightened firmly, typically to 35-50 ft-lbs, to prevent the outer tie rod from rotating during operation. Ensure the outer tie rod boot is properly seated and not twisted.
13. 13

    Repeat procedure for opposite side
    Perform steps 1 through 12 on the opposite side of the vehicle, replacing both inner and outer tie rod ends. Ensure both sides are adjusted to approximately the same length based on your reference marks and measurements.
14. 14

    Reinstall wheels and lower vehicle
    Reinstall both front wheels, threading lug nuts by hand initially. Lower the vehicle until the tires just contact the ground but the suspension is not fully loaded. Torque the lug nuts to manufacturer specification (typically 130-140 ft-lbs for the EDV 500) in a star pattern. Fully lower the vehicle and remove jack stands.
15. 15

    Verify steering operation
    With the vehicle on the ground and in a safe open area, start the vehicle and turn the steering wheel lock-to-lock slowly while stationary. Listen for any unusual noises, binding, or abnormal operation. The electric power steering system should operate smoothly without warning lights on the dashboard. Test drive at low speed in a safe area to verify basic steering response before taking to an alignment shop.

Reassembly

1. All tie rod end boots must be properly seated and secured with clamps to prevent contamination
2. All cotter pins must be new and properly installed through castle nuts
3. Jam nuts must be tightened while holding the outer tie rod to prevent rotation
4. Verify steering wheel returns to center after turning and that steering effort feels normal

Verification

• Schedule and complete a professional four-wheel alignment as soon as possible after this repair
• Verify no play exists in tie rod connections by having an assistant turn the steering wheel slightly while you observe each tie rod end for movement
• Confirm all cotter pins are installed and bent properly
• Test drive vehicle at various speeds and verify straight-line tracking (understanding alignment may be off until professionally aligned)
• Re-torque wheel lug nuts after 50 miles of driving
• After alignment, verify tire pressure monitoring system shows correct values and no warning lights are present

More procedures for this vehicle