Axle Seal - Rear

This procedure covers the replacement of the rear axle seal on a 2022 Rivian EDV 500, including differential fluid drainage, axle shaft removal, seal replacement, and refilling with proper gear oil.

Warnings

Tools required

Parts

• Rear axle seal (driver or passenger side as needed) × 1 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Use OEM specification
• Drain plug washer × 1 — Use OEM specification
• Axle shaft circlip (if applicable) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Verify the vehicle is powered off completely and the key fob is at least 20 feet away from the vehicle
2. Confirm high-voltage system is disabled by checking dashboard indicators
3. Chock the front wheels securely
4. Raise the vehicle on a lift or jack stands, ensuring it is stable and level
5. Remove the rear wheel on the side requiring seal replacement
6. Identify which axle seal is leaking (driver or passenger side) by inspecting for gear oil residue
7. Place drain pan under the rear differential
8. Have all replacement parts, fluids, and tools staged and ready

Procedure

1. 1

   Drain rear differential fluid
   Locate the rear differential drain plug on the bottom of the differential housing. Clean the area around the plug. Using the appropriate socket, remove the drain plug and allow all gear oil to drain completely into the drain pan. Inspect the drained fluid for metal particles or contamination. Remove the fill plug on the side of the differential to ensure complete drainage and ventilation.
2. 2

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and carefully support the caliper with a wire or bungee cord without stressing the brake line. Remove the caliper bracket if it obstructs access to the axle. Remove the brake rotor by pulling it off the hub. If seized, use penetrating oil and light tapping with a rubber mallet.
3. 3

   Disconnect axle shaft from hub assembly
   Remove the axle nut from the center of the hub (this may be a large nut requiring significant torque to break loose). If equipped with ABS sensors or wheel speed sensors, carefully disconnect the electrical connector. Note the routing of any wiring harnesses for reassembly.
4. 4

   Remove suspension components for axle clearance
   Depending on clearance, you may need to disconnect the lower control arm, trailing arm, or other suspension components to provide adequate space to withdraw the axle shaft. Support the suspension with a jack if needed. Mark or photograph component positions for correct reassembly.
5. 5

   Extract axle shaft from differential
   Using a slide hammer with axle adapter or by carefully prying with a pry bar, extract the axle shaft from the differential housing. The shaft may be retained by a circlip inside the differential. Pull the shaft straight out to avoid damaging the differential internals or the seal. If resistance is encountered, verify all fasteners are removed and check for circlip retention.
6. 6

   Remove old axle seal
   With the axle shaft removed, the old seal should be visible in the differential housing bore. Using a seal puller tool or carefully with a pry bar, extract the old seal from the housing. Work around the perimeter of the seal to avoid damaging the seal bore. Clean the seal bore thoroughly with brake cleaner and inspect for any damage, scoring, or wear that could cause the new seal to leak.
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 or appropriately sized socket that contacts only the outer edge of the seal, carefully tap the seal into place until it is fully seated and flush with the housing. Verify the seal is installed evenly and not cocked in the bore.
8. 8

   Inspect and prepare axle shaft
   Thoroughly clean the axle shaft, paying special attention to the seal contact area. Inspect the shaft for any scoring, rust, or damage that could compromise the new seal. If the shaft shows wear in the seal contact area, it should be replaced. Apply a thin coat of gear oil to the seal contact area of the axle shaft.
9. 9

   Reinstall axle shaft
   If equipped with a circlip, install a new circlip in the groove on the inner end of the axle shaft. Carefully guide the axle shaft through the new seal, being extremely careful not to damage the seal lip. Push or tap the shaft into the differential until the circlip engages (you should hear or feel a click). Verify the axle is fully seated by attempting to pull it outward.
10. 10

    Reinstall suspension and hub components
    Reconnect any suspension components that were removed, ensuring all fasteners are tightened properly. Reinstall the axle nut onto the hub and tighten to specification (if no torque spec is available, use 175-200 ft-lbs as a typical value for this vehicle class, but verify with manufacturer data). Reconnect any ABS or wheel speed sensor connectors.
11. 11

    Reinstall brake components
    Reinstall the brake rotor, ensuring it seats properly on the hub. Reinstall the brake caliper bracket (if removed) and the brake caliper itself. Torque all brake fasteners to specification. Verify brake line routing is correct and not pinched or stressed.
12. 12

    Refill rear differential with gear oil
    Install a new drain plug washer on the drain plug and reinstall the drain plug, tightening securely. Using a fluid pump or fill bottle, add 75W-90 GL-5 gear oil through the fill hole until oil begins to drip from the fill hole (indicating proper level). The rear differential capacity is 2.0 quarts. Reinstall and tighten the fill plug.
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle to the ground. Torque the wheel lug nuts to specification in a star pattern (typically 120-140 ft-lbs for this vehicle, verify with manufacturer specification).

Reassembly

1. Ensure all fasteners have been properly tightened to specification
2. Verify no tools or materials have been left in the wheel well or under the vehicle
3. Double-check that all electrical connectors for ABS/wheel speed sensors have been reconnected
4. Confirm brake components are properly installed and brake pedal is firm before moving vehicle

Verification

• With the vehicle on level ground, check the differential fill level by removing the fill plug - gear oil should be at the bottom of the fill hole
• Start the vehicle and verify no warning lights appear on the dashboard related to ABS, traction control, or drivetrain systems
• Test drive the vehicle at low speed in a safe area, checking for unusual noises, vibrations, or handling issues
• After test drive, inspect the axle seal area for any signs of leakage
• Recheck the differential fluid level after the test drive and top off if necessary
• Park the vehicle and inspect again after 24 hours of normal use to confirm no leaks are present

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