Replace the inner CV boot on a 2022 Rivian EDV 500 dual motor AWD electric delivery van, requiring axle removal and disassembly of the inner CV joint.

Warnings

Tools required

Parts

• Inner CV boot kit × 1 — Use OEM specification
• CV joint grease × 1 — Included in boot kit or separate
• Axle nut × 1 — Use OEM specification - replace if worn
• Snap ring (if damaged) × 1 — Use OEM specification

Preparation

1. Ensure vehicle is on level ground and in Park with parking brake engaged
2. Power down the vehicle completely and wait 5 minutes for high-voltage system to discharge
3. Disconnect 12V auxiliary battery negative terminal
4. Loosen the axle nut while vehicle is still on the ground with wheels installed and helper applies brakes
5. Raise vehicle and support securely on jack stands at manufacturer-specified lift points
6. Remove wheel and tire assembly from affected side
7. Place drain pan underneath work area to catch any differential fluid or grease spillage

Procedure

1. 1

   Remove axle nut and suspension components
   Remove the previously loosened 32mm axle nut completely. Remove the brake caliper mounting bolts and secure caliper aside with wire or bungee cord without stressing the brake hose. Remove the lower control arm ball joint nut and use ball joint separator to release the ball joint from the steering knuckle.
2. 2

   Separate outer CV joint from hub
   Push the axle shaft inward through the hub bearing while pulling the steering knuckle outward. If the axle is stuck in the hub, use a soft face hammer to tap it free. Support the axle to prevent it from hanging by the inner CV joint.
3. 3

   Remove axle from transmission/motor unit
   Using a pry bar positioned against the transmission housing and the inner CV joint housing, carefully pry the axle assembly out of the transmission/motor unit. Pull straight out to avoid damaging the differential seal. Be prepared for possible EV transmission fluid drainage. Remove the entire axle assembly from the vehicle.
4. 4

   Secure axle and remove boot clamps
   Mount the axle in a vise using soft jaws at the axle shaft (never clamp on CV joint housings). Use side cutters or boot clamp pliers to cut and remove both clamps securing the inner CV boot. Slide the damaged boot away from the joint toward the center of the shaft.
5. 5

   Mark and disassemble inner CV joint
   Use a paint marker or scribe to mark the relationship between the inner CV joint housing and the tripod/spider assembly on the axle shaft. Wipe away excess grease from the joint. Locate the snap ring or circlip that retains the inner joint housing and remove it using snap ring pliers. Slide the inner CV joint housing off the tripod assembly.
6. 6

   Remove tripod assembly
   Mark the orientation of the tripod bearing assembly on the axle shaft. Remove the snap ring that retains the tripod on the shaft. Use a soft face hammer or brass drift to tap the tripod assembly off the axle shaft, being careful not to lose the needle bearings inside the tripod rollers. If the tripod is tight, apply penetrating oil and use a gear puller.
7. 7

   Clean components and inspect
   Remove the old boot completely from the axle shaft. Clean all CV joint components thoroughly with solvent and dry with compressed air or clean rags. Inspect the tripod bearings, rollers, and inner CV joint housing for wear, pitting, or damage. Check the axle shaft for grooves or damage where the boot seals. Replace any worn components.
8. 8

   Install new boot and reassemble tripod
   Slide the new inner CV boot onto the axle shaft with the small end toward the center. Position it out of the way. Install the tripod assembly onto the shaft in the exact orientation marked during disassembly. Install the tripod retaining snap ring and ensure it is fully seated in its groove.
9. 9

   Pack joint with grease and install housing
   Pack the inner CV joint housing with approximately half of the supplied CV grease. Apply the remaining grease onto the tripod assembly and axle shaft. Align the marks made during disassembly and slide the inner CV joint housing onto the tripod assembly. Install the housing retaining snap ring.
10. 10

    Position and clamp boot
    Slide the new boot over the CV joint housing and into the grooves on both the axle shaft and the joint housing. Ensure the boot is not twisted and sits properly in both grooves. Set the axle to ride height position (neither fully extended nor compressed). Install new boot clamps using the CV boot clamp tool, positioning the small clamp on the axle shaft and the large clamp on the joint housing. Ensure clamps are tight and properly crimped.
11. 11

    Inspect differential seal and reinstall axle
    Inspect the transmission/motor unit differential seal for damage or leakage. Replace if necessary. Clean the axle splines and apply a light coat of EV transmission fluid. Align the axle with the differential and push firmly until you feel the snap ring engage. Give the axle a firm tug to verify it is fully seated and locked in place.
12. 12

    Reinstall outer CV joint and suspension
    Guide the outer CV joint splines through the hub bearing and push fully into place. Reconnect the lower control arm ball joint to the steering knuckle and install the nut. Reinstall the brake caliper with mounting bolts. Install the new or cleaned axle nut and tighten finger-tight only at this stage.

Reassembly

1. Reinstall wheel and tire assembly with lug nuts torqued to specification
2. Lower vehicle to ground before final axle nut torque
3. With vehicle on ground and brakes applied, torque the axle nut to manufacturer specification (consult service manual for exact value, typically 180-220 lb-ft for similar EVs)
4. Stake or install cotter pin through axle nut if equipped
5. Reconnect 12V auxiliary battery negative terminal
6. Check and top off EV transmission fluid if any was lost during axle removal
7. Start vehicle and verify proper operation of all systems

Verification

• Test drive vehicle at various speeds and listen for clicking, popping, or vibration from the CV joint area
• Turn steering wheel to full lock in both directions while moving slowly to verify no noise from CV joints
• Visually inspect the new boot for proper seating, correct positioning, and secure clamps
• Check for any leaks around the differential seal and boot
• Verify no warning lights or error codes related to drivetrain or ABS systems
• Inspect differential fluid level if accessible and top off if necessary with 75W-90 GL-5 gear oil

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