This procedure covers the replacement of the front axle seal on a 2022 Rivian EDV 500, requiring removal of the front halfshaft and differential seal replacement.

Warnings

Tools required

Parts

• Front differential axle seal × 1 — Use OEM specification
• Halfshaft retaining clip (if reusable clip is damaged) × 1 — Use OEM specification
• Differential drain plug gasket or crush washer × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Power off vehicle completely using main power switch
3. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
4. If available, place vehicle in service mode using diagnostic tool
5. Lift vehicle and secure on jack stands rated for EV weight
6. Remove front wheel on affected side
7. Clean area around differential fill and drain plugs thoroughly

Procedure

1. 1

   Drain front differential fluid
   Position drain pan under front differential. Remove the differential fill plug first to break the vacuum, then remove drain plug and allow fluid to drain completely. Inspect drained fluid for metal particles or contamination that may indicate additional problems.
2. 2

   Remove front halfshaft axle nut
   Have an assistant apply brake pedal or use a pry bar to prevent wheel hub rotation. Use breaker bar and appropriate socket to remove the front axle nut. This nut is typically torqued very tight and may require significant force to loosen.
3. 3

   Disconnect lower control arm or support components
   Remove fasteners securing lower control arm ball joint or any suspension components that interfere with halfshaft removal. Support the control arm with a jack stand to prevent strain on other suspension components. Document fastener locations and any variations in hardware.
4. 4

   Remove halfshaft from differential
   Using a pry bar between the inner CV joint and differential housing, carefully pry the halfshaft from the differential. Apply even pressure and be prepared for the shaft to release suddenly. Note the installed depth of the halfshaft for reassembly reference. Remove the halfshaft from the vehicle, supporting both ends to prevent CV joint damage.
5. 5

   Remove old axle seal
   Using an axle seal puller or slide hammer with appropriate adapter, carefully extract the old seal from the differential housing. Work evenly around the seal to prevent cocking. If using a pry bar as alternative, take extreme care not to damage the seal bore surface in the differential housing.
6. 6

   Clean and inspect seal bore
   Thoroughly clean the seal bore in the differential housing using clean rags and appropriate solvent. Inspect the bore for scoring, corrosion, or damage. Use a wire brush if needed to remove any rust or debris. Check the halfshaft seal surface for wear grooves or damage that could cause premature seal failure.
7. 7

   Install new axle seal
   Lightly coat the outer diameter of the new seal with gear oil. Position the seal squarely in the bore with the seal lip facing inward toward the differential. Using a seal driver of appropriate size or a large socket that contacts only the outer edge of the seal, carefully drive the seal into place until it seats fully and is flush with the housing. Tap evenly around the perimeter to ensure proper seating.
8. 8

   Lubricate seal and prepare halfshaft
   Apply fresh 75W-90 GL-5 gear oil to the new seal lip and halfshaft splines. Inspect the halfshaft retaining clip (circlip) for damage or deformation. If the clip shows any signs of weakness or permanent deformation, replace it with a new clip. Ensure the clip is properly seated in the halfshaft groove.
9. 9

   Reinstall halfshaft into differential
   Align the halfshaft splines with the differential side gear. Push the shaft firmly into the differential until the retaining clip engages with an audible click. Pull outward on the halfshaft to verify it is properly locked in place. The shaft should not pull out of the differential.
10. 10

    Reconnect suspension components
    Reinstall the lower control arm ball joint or any suspension components removed earlier. Install all fasteners and tighten progressively. Without factory torque specifications, inspect fasteners for any markings indicating torque-to-yield or thread locking requirements.
11. 11

    Install axle nut
    Install the front axle nut onto the halfshaft. Have an assistant apply the brake or use appropriate method to prevent hub rotation. Tighten the axle nut progressively. Without factory specifications, tighten firmly and inspect for any thread locking compound indicating specific torque requirements. Note whether the nut appears to be torque-to-yield type.
12. 12

    Refill front differential
    Install new drain plug gasket or crush washer and reinstall drain plug, tightening securely. Using a fluid pump, add 1.5 quarts of 75W-90 GL-5 gear oil through the fill hole until fluid begins to drip from the fill opening. Install fill plug with new gasket if applicable and tighten securely.
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the front wheel and tighten lug nuts in a star pattern. Lower vehicle to ground and perform final torque on lug nuts according to manufacturer specifications (typically 130-140 ft-lbs for this vehicle class, though verify with Rivian documentation).

Reassembly

1. Reconnect 12V auxiliary battery negative terminal
2. Power on vehicle and verify no warning lights or error codes related to drivetrain systems
3. If service mode was activated, exit service mode using diagnostic tool
4. Clean any spilled gear oil from undercarriage and components

Verification

• With vehicle on level ground, check differential fluid level at fill plug - oil should be at bottom of fill hole threads
• Test drive vehicle at low speed and verify no clicking, popping, or unusual noises from front axle
• After test drive, inspect seal area for any signs of leakage while vehicle is raised
• Recheck differential fluid level after test drive and top off if necessary
• After 50-100 miles, reinspect seal area and differential fluid level to confirm proper seal installation

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