Replace the outer CV boot on a 2022 Rivian EDV 500 to prevent contaminants from entering the CV joint and restore proper sealing.

Warnings

Tools required

Parts

• Outer CV boot kit with clamps and grease × 1 — Use OEM specification
• Axle nut (single-use) × 1 — Use OEM specification
• Differential drain plug gasket × 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. Follow manufacturer procedures to isolate high-voltage system and display isolation verification
3. Loosen front axle nut while vehicle is on ground (have assistant apply brakes)
4. Raise vehicle on lift or jack stands rated for EV weight
5. Remove front wheel on side being serviced
6. Place drain pan under differential to catch fluid spillage

Procedure

1. 1

   Remove axle nut and wheel speed sensor
   Remove the previously loosened axle nut completely and set aside (do not reuse). Disconnect the wheel speed sensor electrical connector and unbolt the sensor from the knuckle to prevent damage during removal.
2. 2

   Disconnect lower control arm
   Remove the bolt securing the lower control arm ball joint to the steering knuckle. If necessary, use a ball joint separator to break the taper free. Support the lower control arm to prevent it from dropping.
3. 3

   Disconnect outer tie rod end
   Remove the outer tie rod end castle nut and use a ball joint separator to disconnect the tie rod from the knuckle. Do not damage the tie rod boot during separation.
4. 4

   Support hub assembly
   Support the hub and knuckle assembly with a bungee cord or wire to prevent the assembly from hanging on the brake hose when the axle is removed. Ensure brake hose is not under tension.
5. 5

   Remove axle from differential
   Using a pry bar positioned against the differential case and the inner CV joint housing, carefully pry the axle shaft from the differential. You should feel the circlip release. Be prepared for differential fluid to drain. Pull the axle straight out to avoid damaging the differential seal.
6. 6

   Remove axle from hub
   Push the outer end of the axle shaft through the hub bearing. If the shaft is stuck, use a brass drift from the backside to tap it through. Remove the entire axle assembly from the vehicle.
7. 7

   Remove old outer CV boot
   Place the axle in a padded vise, clamping on the shaft (not the CV joint). Cut off the old boot clamps with side cutters. Slide the old boot toward the center of the shaft. Thoroughly clean the CV joint housing, axle shaft, and surrounding area with degreaser.
8. 8

   Inspect CV joint
   Carefully inspect the outer CV joint for wear, pitting, or damage. Rotate the joint through its full range of motion while feeling for roughness, clicking, or binding. If the joint shows any damage, the entire axle should be replaced rather than just the boot.
9. 9

   Install new CV boot
   Slide the new small boot clamp onto the axle shaft, followed by the new boot, then the large clamp. Position the small end of the boot in the groove on the axle shaft and secure with the clamp using CV boot clamp pliers. Ensure the clamp is tight and properly seated.
10. 10

    Pack CV joint with grease
    Pack the entire CV joint with the grease provided in the boot kit. Work the grease into all areas of the joint by rotating it by hand. Place any remaining grease inside the boot. The joint should be completely full of grease.
11. 11

    Seat and secure outer boot end
    Position the large end of the boot onto the CV joint housing groove. Ensure the boot is not twisted and sits properly in both grooves. Release any trapped air by carefully lifting the boot lip. Install and tighten the large clamp using the boot clamp tool.
12. 12

    Reinstall axle into hub
    Apply a thin layer of anti-seize to the axle splines. Insert the outer end of the axle through the hub bearing until it is fully seated. Ensure the splines engage properly.
13. 13

    Install axle into differential
    Clean the differential seal area and check seal condition. Align the inner CV joint with the differential opening and push firmly until the circlip seats with an audible click. Verify the axle is fully engaged by attempting to pull it out.
14. 14

    Reconnect suspension components
    Reconnect the outer tie rod end to the steering knuckle and install the castle nut. Reconnect the lower control arm ball joint to the knuckle and install the bolt. Do not fully torque fasteners until vehicle is at ride height.
15. 15

    Final assembly
    Install the wheel speed sensor and reconnect the electrical connector. Install the new axle nut and snug by hand. Install the wheel and lower the vehicle to the ground. With the vehicle at ride height, torque all suspension fasteners and the axle nut to specification per service manual. Top off differential with 75W-90 GL-5 gear oil to proper level.

Reassembly

1. All suspension fasteners must be torqued with vehicle at ride height to prevent premature bushing failure
2. Use a new axle nut as original is single-use and designed to deform
3. Verify differential is filled to proper level after axle installation
4. If equipped with axle nut staking, properly stake the new nut per manufacturer procedure

Verification

• Perform visual inspection of CV boot to ensure proper seating and no twisting
• Check that boot clamps are tight and properly positioned in grooves
• Verify differential fluid level is correct and no leaks are present
• Test drive vehicle at low speed and verify no clicking, popping, or vibration from the CV joint
• Turn steering wheel full lock in both directions while driving slowly to verify CV joint operates smoothly
• Inspect for any differential leaks after test drive
• Verify wheel speed sensor is functioning properly with no ABS warnings

More procedures for this vehicle