drivetrain

CV Axles - Front Pair

for 2022 Rivian EDV 500 Dual Motor AWD (EDV) · AWD

Difficulty

Advanced

Time

5.2 h

Tools

Steps

🤖AI-generated, not yet human-verified. This walkthrough was produced by AI and may contain errors. Treat it as a guide, cross-check every step and torque value against the manufacturer's service manual, and stop if anything looks unsafe. This is a moderate-risk job — take extra care.

This procedure covers the removal and installation of both front CV axles on the 2022 Rivian EDV 500 electric delivery van, including proper drivetrain disassembly and differential fluid handling.

Warnings

⚠️This is a heavy commercial electric vehicle. Ensure lift or jack stands are rated for minimum 9,000 lbs capacity and properly positioned on manufacturer-specified lift points.

⚠️Disable high voltage system and wait minimum 5 minutes before beginning work. Use insulated gloves when working near orange high voltage cables.

⚠Front differential fluid will drain when CV axles are removed. Have drain pan positioned before axle extraction.

⚠CV axles are under spring tension from suspension load. Support lower control arms before removing axle nuts.

ℹ️New axle nuts must be used and should not be reused per manufacturer specification.

Tools required

Vehicle lift or jack stands rated for commercial vehicle weightEssential

Torque wrench (ft-lb range)Essential

Pry bar or CV axle separator toolEssential

Drain pan (minimum 2 quart capacity)Essential

Socket set (metric)Essential

Breaker barEssential

Hammer (dead blow or brass)

Wire brush

Seal puller or pick set

Rubber mallet

Fluid pump for differential refillEssential

Wheel chocksEssential

Parts

Front CV axle assembly - driver side × 1 — Use OEM specification
Front CV axle assembly - passenger side × 1 — Use OEM specification
Front differential seal - driver side × 1 — Use OEM specification
Front differential seal - passenger side × 1 — Use OEM specification
Axle nut - front × 2 — Use OEM specification
Front differential drain plug washer × 1 — Use OEM specification
Front differential fill plug washer × 1 — Use OEM specification

Fluids

75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

Park vehicle on level surface and engage parking brake
Place wheel chocks behind rear wheels
Disconnect 12V battery negative terminal
Follow manufacturer lockout/tagout procedure to disable high voltage system
Raise vehicle on lift or use jack stands at manufacturer-specified lift points
Remove both front wheels
Mark CV axle orientation relative to hubs for reference during installation

Procedure

1
Remove front axle nuts
With vehicle on ground or with helper applying brakes, use breaker bar to loosen both front axle nuts. Once loosened, raise vehicle and remove nuts completely. These nuts are single-use and must be replaced.
2
Support lower control arms
Place jack stands or hydraulic jack under both lower control arms to support suspension load. This prevents sudden drop when CV axle is disconnected from hub and maintains proper suspension geometry during service.
3
Disconnect brake caliper and rotor access
Remove brake caliper mounting bolts and secure caliper to suspension or frame with wire or bungee cord. Do not let caliper hang by brake hose. Remove brake rotor if additional clearance is needed for axle removal.
4
Separate CV axle from wheel hub
Remove hub mounting bolts connecting the CV axle outer joint to the wheel hub assembly. If axle is stuck in hub splines, use plastic mallet to tap end of axle shaft while pulling hub assembly outward. Do not damage ABS sensor or wiring during separation.
5
Drain front differential fluid
Position drain pan under front differential. Remove differential drain plug and allow fluid to drain completely. Inspect drained fluid for metal particles or contamination that may indicate internal damage. Remove and discard drain plug washer.
6
Remove driver side CV axle from differential
Using pry bar or CV axle removal tool, carefully pry inner CV joint from front differential housing. Insert pry bar between differential housing and inner CV joint housing, applying steady pressure to disengage retaining clip. Once clip releases, pull axle straight out. Some residual fluid will drain - keep drain pan positioned.
7
Remove passenger side CV axle from differential
Repeat removal process for passenger side CV axle. Use pry bar to disengage retaining clip from differential and pull axle assembly straight out. Note orientation of any shims or spacers present during removal.
8
Remove and replace differential seals
Using seal puller or pick tool, carefully extract old differential seals from both sides of front differential housing. Clean seal bore thoroughly with wire brush and inspect for damage or scoring. Install new seals using appropriate seal driver or large socket, ensuring seals are seated squarely and flush with housing face.
9
Install driver side CV axle
Lubricate new differential seal lips with fresh gear oil. Align driver side CV axle splines with differential side gear. Push axle firmly into differential until retaining clip engages with positive click. Verify axle is fully seated by attempting to pull it back out - it should not move.
10
Install passenger side CV axle
Repeat installation for passenger side CV axle. Lubricate seal, align splines, and push axle into differential until retaining clip engages. Confirm full engagement by pulling on axle shaft.
11
Connect CV axles to wheel hubs
Guide outer CV joint splines into wheel hub assemblies on both sides. Install hub mounting bolts and tighten in star pattern. Slide new axle nuts onto axle shafts but do not tighten yet.
12
Refill front differential
Install new washer on differential drain plug and reinstall plug. Using fluid pump, refill front differential with 1.5 quarts of 75W-90 GL-5 gear oil through fill port. Fluid is at correct level when it begins to seep from fill hole. Install fill plug with new washer.
13
Reinstall brake components
Reinstall brake rotors if removed. Remount brake calipers using proper mounting bolts and tighten to specification. Ensure brake hoses are not twisted or kinked.
14
Torque axle nuts
Install front wheels and lower vehicle until tires contact ground but vehicle weight is not fully on suspension. With helper applying brakes or vehicle in park on level surface, torque both front axle nuts to manufacturer specification using torque wrench. Note: Torque specification not available in database - consult factory service manual for exact value.

Reassembly

Remove lower control arm supports
Install front wheels and torque lug nuts to specification
Lower vehicle completely to ground
Reconnect 12V battery negative terminal
Follow manufacturer procedure to re-enable high voltage system
Pump brake pedal several times to restore brake pressure before moving vehicle

Verification

Test drive vehicle at low speed and listen for clicking, popping, or grinding noises from front axles during turns
Verify no vibration is present during acceleration or at highway speeds
Inspect both CV axle boots for proper seating and no tears or damage
Check for differential fluid leaks around both axle seals after test drive
Verify differential fluid level is correct - top off if needed
Confirm no ABS warning lights are present and wheel speed sensors are functioning properly
Re-torque axle nuts after first 50-100 miles of driving