This procedure covers the removal and replacement of a front CV axle assembly on a 2022 Rivian EDV 500 electric delivery van with dual motor all-wheel drive.

Warnings

Tools required

Parts

• Front CV axle assembly (left or right as needed) × 1 — Use OEM Rivian specification
• Axle nut × 1 — Use OEM specification - single use
• Front differential seal × 1 — Use OEM specification
• Lower control arm ball joint nut (if damaged) × 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. Place wheel chocks behind rear wheels
3. Access the vehicle's service mode through the driver display to disable the high-voltage system
4. Wait 5 minutes after HV isolation for capacitor discharge
5. Disconnect the 12V auxiliary battery negative terminal
6. Raise vehicle on lift or jack stands at manufacturer-specified lift points
7. Remove the front wheel on the side requiring axle replacement
8. Have replacement CV axle and all parts ready before beginning disassembly

Procedure

1. 1

   Remove wheel center cap and loosen axle nut
   Remove the center cap from the wheel hub. With the vehicle still on the ground (or have an assistant apply brakes), use a 32mm socket and breaker bar to loosen but do not remove the front axle nut. This nut is torqued to very high specification and requires significant force.
2. 2

   Access the CV axle area
   With the wheel removed, inspect the CV axle boot condition and verify which side requires replacement. Clean the area around the axle nut, hub, and lower control arm ball joint with a wire brush to remove dirt and corrosion.
3. 3

   Disconnect lower control arm ball joint
   Remove the lower control arm ball joint nut. Use a ball joint separator tool or pickle fork to separate the ball joint from the steering knuckle. Be careful not to damage the ball joint boot if reusing the control arm.
4. 4

   Remove brake caliper bracket
   Remove the brake caliper and bracket assembly as a complete unit. Support the caliper with wire or a bungee cord to prevent strain on the brake hose. Do not let the caliper hang by the brake line.
5. 5

   Position drain pan and remove axle nut
   Position a drain pan under the front differential area where the CV axle enters. The differential is located within the front motor housing. Now completely remove the loosened axle nut from the hub. Mark or photograph the axle nut orientation if it has a specific installation direction.
6. 6

   Separate CV axle from hub
   With the axle nut removed, push the axle shaft out of the wheel hub. If the axle is stuck in the hub splines, use a plastic dead blow hammer to tap the end of the shaft while supporting the hub. Do not strike with excessive force or you may damage the hub bearing.
7. 7

   Remove CV axle from differential
   Using a pry bar positioned between the inner CV joint and the differential housing, carefully pry the axle out of the differential. You should feel the circlip release as the axle separates. Differential fluid will drain at this point. Keep the drain pan positioned to catch fluid. Remove the CV axle assembly from the vehicle.
8. 8

   Inspect and replace differential seal
   Inspect the differential output shaft seal for damage or leaking. The seal should be replaced whenever the axle is removed. Use a seal puller or screwdriver to carefully remove the old seal without damaging the housing bore. Clean the seal bore thoroughly.
9. 9

   Install new differential seal
   Install the new differential seal using a seal driver or appropriately sized socket. Drive the seal in evenly until it is flush with the housing face. Apply a thin coat of gear oil to the seal lip before installing the new axle.
10. 10

    Install new CV axle into differential
    Ensure the circlip is properly seated on the inner CV joint splines of the new axle. Align the splines and push the axle firmly into the differential until you feel and hear the circlip snap into place. Give the axle a firm pull outward to verify the circlip has engaged properly.
11. 11

    Install CV axle into wheel hub
    Guide the outer CV joint shaft through the wheel hub and start the splines by hand. Ensure the shaft is fully seated into the hub bearing. Install the new axle nut finger-tight at this stage.
12. 12

    Reconnect lower control arm ball joint
    Position the lower control arm ball joint into the steering knuckle. Install the ball joint nut and tighten to specification. If the nut has a castle design, align with the cotter pin hole and install a new cotter pin.
13. 13

    Reinstall brake caliper bracket
    Reinstall the brake caliper and bracket assembly. Ensure the brake pads are properly positioned over the rotor. Tighten all caliper bracket bolts to specification.
14. 14

    Torque axle nut and refill differential
    With an assistant applying the brakes or after reinstalling the wheel, torque the front axle nut to manufacturer specification (typically 175-200 ft-lbs for this class of vehicle, but verify with Rivian service data as no torque specs are provided). Refill the front differential with 1.5 quarts of 75W-90 GL-5 gear oil through the fill port until fluid reaches the bottom of the fill hole.
15. 15

    Final installation and system checks
    Install the wheel center cap. Reinstall the wheel and torque lug nuts to specification. Lower the vehicle. Reconnect the 12V battery. Exit service mode and restore high-voltage system operation through the vehicle display. Test drive the vehicle and verify no vibration, noise, or warning lights.

Reassembly

1. Torque all fasteners to manufacturer specifications in the proper sequence
2. Verify the axle circlip is properly engaged by pulling outward on the installed axle
3. Ensure differential is filled to proper level before driving
4. Double-check that brake caliper bolts are properly torqued before test drive
5. Install a new axle nut - these are typically single-use torque-to-yield fasteners

Verification

• Test drive the vehicle at various speeds and verify no vibration or clicking noises from the CV axle
• Check for differential fluid leaks around the new seal after test drive
• Verify no warning lights are present on the instrument cluster
• Confirm proper operation of the front motor and AWD system
• Recheck axle nut torque after 50-100 miles of driving
• If equipped, verify vehicle systems with diagnostic scan tool show no faults

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