Axle Shaft - Rear

This procedure covers the removal and replacement of the rear axle shaft on a 2022 Rivian EDV 500 electric delivery van with dual motor AWD configuration.

Warnings

Tools required

Parts

• Rear axle shaft assembly × 1 — Use OEM specification
• Axle seal (differential side) × 1 — Use OEM specification
• Wheel hub bearing assembly (if applicable) × 1 — Use OEM specification
• Differential cover gasket × 1 — Use OEM specification
• Brake caliper mounting bolts (if reusing is not recommended) × 2 — Use OEM specification
• Axle nut (single-use) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil (rear differential) — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V negative battery terminal and wait 5 minutes for system capacitors to discharge
3. Verify high-voltage system is de-energized using approved HV safety procedures
4. Raise vehicle on lift or jack stands at manufacturer-specified lift points
5. Remove rear wheel on side being serviced
6. Place wheel chocks at front wheels
7. Document rear differential fluid condition before draining (color, debris, odor)

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and carefully support the caliper with a wire or bungee cord to avoid stressing the brake hose. Do not let the caliper hang by the brake line. Remove the brake rotor by removing any retaining screws if present. The rotor should slide off the hub.
2. 2

   Remove axle nut
   Have an assistant apply brakes or use a wheel holding tool to prevent rotation. Remove the center axle nut using a breaker bar and appropriate socket. This nut is typically very tight and may require significant force. Discard the nut as it is single-use and should not be reused.
3. 3

   Disconnect wheel speed sensor
   Locate the wheel speed sensor connector near the knuckle or trailing arm. Disconnect the electrical connector by depressing the locking tab. If equipped with a mounting bracket, remove the sensor wire from any retaining clips along the suspension to provide clearance for axle removal.
4. 4

   Drain rear differential
   Position drain pan under the rear differential drain plug. Remove the differential drain plug and allow fluid to drain completely. Inspect drained fluid for metal particles or debris that may indicate internal damage. Once drained, temporarily reinstall drain plug finger-tight to prevent contamination.
5. 5

   Remove differential cover (if required)
   Some axle shaft removal procedures require differential cover removal for internal access. If applicable to your specific failure mode, remove all differential cover bolts in a cross-pattern to prevent warping. Carefully separate the cover from the housing using a non-marring pry tool. Remove and discard the old gasket material from both mating surfaces.
6. 6

   Remove suspension components for axle clearance
   Depending on axle shaft design, you may need to disconnect the lower control arm, trailing arm, or toe link at the knuckle. Remove the fasteners connecting these components to the knuckle to create enough movement to extract the axle shaft. Support the suspension components to prevent damage to bushings or other connections.
7. 7

   Separate axle shaft from wheel hub
   Using a brass drift or plastic mallet, tap the end of the axle shaft to break it free from the hub splines. If the shaft is seized in the hub, use a hub puller or press to separate them. Be careful not to damage the hub bearing or ABS tone ring during this process. Once separated, push the hub assembly outward to clear the axle shaft splines.
8. 8

   Remove axle shaft from differential
   Attach the slide hammer with axle puller adapter to the inner end of the axle shaft. Use firm, steady pulls to extract the shaft from the differential. The shaft should slide out along with the inner seal. If the shaft is equipped with circlips or retaining rings, these will release as the shaft is withdrawn. Be prepared to catch any residual gear oil that may drain from the differential opening.
9. 9

   Remove and inspect axle seal
   Once the axle shaft is removed, inspect the differential-side seal. Use a seal puller or small pry bar to carefully remove the old seal from the differential housing. Take care not to damage the sealing surface in the housing. Inspect the seal bore for scoring, corrosion, or damage that could cause the new seal to leak.
10. 10

    Inspect differential and bearings
    With the axle removed, visually inspect the differential side gears, spider gears, and bearing surfaces for wear, pitting, or damage. Check the axle shaft splines on both the differential and hub sides for wear or twisting. Inspect the CV joint boots (if equipped) for tears or grease leakage. Replace any components showing abnormal wear.
11. 11

    Install new axle seal
    Lightly coat the outer diameter of the new axle seal with gear oil. Using an appropriately sized seal driver or large socket that contacts only the outer edge of the seal, tap the seal squarely into the differential housing until it is fully seated and flush with the housing surface. Verify the seal is not cocked or damaged during installation.
12. 12

    Install new axle shaft
    Lightly coat the axle shaft splines and seal contact area with clean gear oil. Carefully guide the inner end of the axle shaft into the differential, aligning the splines with the side gear. Push firmly until you feel or hear the retaining ring engage (if equipped). The shaft should be fully seated in the differential with minimal axial play. Verify proper engagement by attempting to pull the shaft outward—it should not withdraw.
13. 13

    Reinstall differential cover and fill with fluid
    If the differential cover was removed, install a new gasket and reinstall the cover. Tighten bolts in a cross-pattern to ensure even seating. Remove the differential fill plug and add the specified 75W-90 GL-5 gear oil (approximately 2.0 quarts for rear differential) until fluid reaches the bottom of the fill hole. Reinstall fill plug. Verify drain plug is properly tightened.
14. 14

    Reconnect hub and suspension components
    Guide the outer end of the axle shaft through the hub bearing, aligning the splines. You may need to rotate the hub slightly to engage the splines. Once aligned, push the hub onto the shaft until fully seated. Reconnect any suspension components that were disconnected (control arms, trailing arms, toe links) and install fasteners.
15. 15

    Install new axle nut and final assembly
    Install the new axle nut onto the shaft threads. Have an assistant apply the brakes or use a holding tool, then torque the axle nut to specification (refer to service manual—typically 150-200 lb-ft for this class of vehicle, but verify). Reinstall the brake rotor and caliper. Reconnect the wheel speed sensor and secure wiring in original routing. Install the wheel and torque lug nuts to specification.

Reassembly

1. Torque all suspension fasteners to manufacturer specifications
2. Verify brake caliper mounting bolts are properly torqued
3. Ensure wheel speed sensor connector is fully seated and locked
4. Double-check differential fluid level at fill plug—fluid should be at the bottom edge of fill hole
5. Reconnect 12V battery negative terminal
6. Clear any diagnostic trouble codes related to wheel speed sensor disconnect

Verification

• Lower vehicle and perform a visual inspection under the vehicle for any fluid leaks around the differential cover and axle seal
• Test drive the vehicle at low speed (under 25 mph) in a safe area and listen for any unusual noises from the rear axle
• Check for vibrations during acceleration and deceleration that could indicate improper axle installation or imbalanced components
• Verify ABS and traction control systems function properly with no warning lights
• Re-inspect differential fluid level after test drive and top off if necessary
• Inspect axle seal area for any signs of fresh fluid leakage after 50-100 miles of operation
• Verify proper torque on all suspension and drivetrain fasteners after test drive

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