This procedure covers the removal and replacement of the Battery Junction Box on the 2022 Rivian EDV 500, which distributes high voltage power from the battery pack to vehicle systems.

Warnings

Tools required

Parts

• Battery Junction Box × 1 — Use OEM specification
• High voltage connector seals × 1 — Use OEM specification
• Mounting hardware kit × 1 — Use OEM specification
• High voltage warning labels × 1 — Use OEM specification

Preparation

1. Ensure vehicle is parked on level ground in a well-ventilated area
2. Verify technician has completed high voltage safety training and certification
3. Connect Rivian diagnostic tool and document any existing fault codes
4. Ensure vehicle is powered off completely and key fob is at least 20 feet away
5. Allow vehicle to sit for minimum 10 minutes to allow capacitors to discharge
6. Put on all required high voltage safety equipment including insulated gloves and safety glasses
7. Place high voltage warning signs around vehicle work area
8. Remove 12V auxiliary battery negative terminal and secure away from post
9. Raise vehicle on lift to access undercarriage components

Procedure

1. 1

   Access high voltage disconnect
   Remove underbody panels as necessary to access the manual high voltage service disconnect. This is typically located near the battery pack. Remove any protective covers and access panels using appropriate trim tools.
2. 2

   Perform high voltage lockout/tagout
   Pull the manual high voltage service disconnect to de-energize the high voltage system. Remove the disconnect switch and store in your pocket or secure location to prevent accidental reconnection. Apply lockout/tagout tag to the disconnect location.
3. 3

   Verify high voltage system is de-energized
   Wait minimum 5 minutes for high voltage capacitors to discharge. Using a calibrated high voltage multimeter with appropriate insulated test leads, verify zero voltage at multiple high voltage connection points. Test between positive and negative busbars, and each busbar to chassis ground. All readings must be below 5V DC before proceeding.
4. 4

   Access Battery Junction Box location
   The Battery Junction Box is located on top of the battery pack assembly in the underbody area. Remove any additional underbody panels, protective covers, or cross members that obstruct access to the junction box mounting area. Document wire routing with photos.
5. 5

   Disconnect low voltage connections
   Disconnect all low voltage signal connectors from the Battery Junction Box. These include communication harnesses, sensor connections, and control module interfaces. Press release tabs and pull connectors straight out to avoid pin damage. Label each connector for reinstallation.
6. 6

   Disconnect high voltage cables
   Working with one connection at a time, remove high voltage cable connections from the Battery Junction Box. Remove securing hardware using insulated tools. Support cable weight to prevent strain on connection points. Mark each cable position and orientation. Inspect seals and replace if damaged.
7. 7

   Remove coolant lines if equipped
   If the Battery Junction Box has integrated cooling, carefully disconnect coolant lines. Place drain pan underneath to catch any coolant spillage. Use appropriate line disconnect tools to avoid damaging quick-connect fittings. Cap open lines to prevent contamination.
8. 8

   Remove junction box mounting fasteners
   Remove all mounting bolts securing the Battery Junction Box to the battery pack assembly. Support the junction box weight during removal of final fasteners. Note the location of any ground straps or brackets that must be reinstalled.
9. 9

   Remove Battery Junction Box
   Carefully lower the Battery Junction Box from its mounting location. The unit is heavy and contains sensitive electronics, so support it properly and avoid impact or dropping. Move to clean, static-free work surface if inspection or component transfer is needed.
10. 10

    Prepare new Battery Junction Box
    Inspect new Battery Junction Box for shipping damage. Transfer any necessary components from old unit if specified by service procedure (verify with Rivian service information). Ensure all mounting surfaces are clean and free of debris. Install new seals and gaskets as required.
11. 11

    Install new Battery Junction Box
    Position new Battery Junction Box into mounting location, ensuring proper alignment with all connection points and mounting holes. Start all mounting bolts by hand to ensure proper thread engagement. Reinstall any ground straps in their original locations.
12. 12

    Torque mounting fasteners
    Torque all Battery Junction Box mounting bolts in a cross-pattern sequence to ensure even clamping force. Since no torque specifications are provided in the database, follow torque values specified on the component label or in Rivian service documentation. Verify all fasteners are secure.
13. 13

    Reconnect coolant lines
    If equipped with cooling, reconnect coolant lines to the Battery Junction Box. Ensure quick-connect fittings are fully seated and locked. Verify correct routing without kinks or excessive strain on lines.
14. 14

    Reconnect high voltage cables
    Reconnect high voltage cables to the Battery Junction Box in their original positions. Install new connector seals if provided. Ensure cables are fully seated and securing hardware is properly torqued per service documentation. Verify positive cable identification and routing.
15. 15

    Reconnect low voltage connections
    Reconnect all low voltage signal connectors to the Battery Junction Box. Ensure each connector clicks into place and locking tabs are fully engaged. Verify correct connector pairing using labels from disassembly. Route wiring to avoid pinch points.

Reassembly

1. Reinstall all underbody panels, protective covers, and cross members in reverse order of removal
2. Ensure all high voltage warning labels are in place and legible
3. Verify all wire routing matches original configuration and no wires are pinched or stressed
4. Reconnect 12V auxiliary battery negative terminal
5. Lower vehicle from lift
6. Reinstall manual high voltage service disconnect and verify secure installation
7. Remove lockout/tagout tag and high voltage warning signs

Verification

• With high voltage still disconnected, use Rivian diagnostic tool to verify Battery Junction Box communication and no installation-related fault codes
• Perform visual inspection of all connections ensuring nothing was missed
• Reconnect high voltage service disconnect and allow vehicle systems to initialize
• Power up vehicle and verify no high voltage system fault codes present
• Monitor Battery Junction Box and all connections for proper operation during initial power-up
• Perform high voltage isolation test using diagnostic tool to verify system integrity
• Check coolant level if system has cooling lines and top off as necessary
• Test drive vehicle to verify all electric drive functions operate normally
• Perform final diagnostic scan and verify no fault codes present
• Document all work performed and any fault codes cleared in vehicle service records

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