Replace the differential cover gasket on the front and/or rear differential assembly, requiring fluid drainage, cover removal, gasket replacement, and refilling with specified gear oil.

Warnings

Tools required

Parts

• Differential cover gasket × 1 — Use OEM Rivian specification for front or rear differential
• Differential cover bolt set (if damaged) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil (front differential) — 1.5 qt
• 75W-90 GL-5 Gear Oil (rear differential) — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks at wheels opposite to the differential being serviced
3. Disconnect 12V battery negative terminal and wait 2 minutes
4. Enable Service Mode through vehicle settings if available
5. Raise vehicle using appropriate lift or jack stands rated for electric vehicle weight
6. Remove wheel(s) corresponding to the differential being serviced
7. Position drain pan under differential cover
8. Allow differential to cool if vehicle was recently operated

Procedure

1. 1

   Access the differential cover
   Remove any underbody panels or skid plates that obstruct access to the differential cover. On the EDV 500, this may include plastic undertray panels secured with push clips or fasteners. Store all hardware in a container for reinstallation.
2. 2

   Clean the differential cover exterior
   Spray the differential cover and surrounding area with brake cleaner or degreaser to remove road debris and grime. Wipe clean with shop towels. This prevents contamination when the cover is removed.
3. 3

   Loosen differential cover bolts
   Identify all differential cover bolts (typically 10-12 bolts in a circular pattern). Begin loosening all bolts in a crisscross pattern, turning each bolt 2-3 turns. Do not remove bolts completely yet. This allows fluid to drain in a controlled manner.
4. 4

   Drain gear oil
   With drain pan positioned under the lower edge of the differential cover, carefully remove the lower bolts first. Allow gear oil to drain from the bottom. Tilt the cover slightly if needed to encourage complete drainage. Once flow slows significantly, remove remaining bolts and carefully lower the cover, allowing remaining oil to drain into pan.
5. 5

   Remove differential cover
   Fully remove the differential cover from the housing. If cover is stuck due to old gasket material, gently tap around the perimeter with a rubber mallet. Do not pry with metal tools as this can damage sealing surfaces. Set cover aside on clean surface.
6. 6

   Inspect differential internals
   With cover removed, visually inspect the differential gears and housing interior for metal shavings, scoring, or unusual wear. Small amounts of fine metallic residue on the magnetic drain plug is normal. Any large metal pieces or excessive debris indicates potential internal damage requiring further diagnosis.
7. 7

   Clean differential housing mating surface
   Using a plastic gasket scraper, carefully remove all old gasket material from the differential housing mating surface. Be extremely careful not to gouge or scratch the aluminum surface. Follow with brake cleaner and lint-free towels to ensure surface is completely clean and dry.
8. 8

   Clean differential cover and mating surface
   Remove old gasket material from the differential cover using plastic scraper. Clean thoroughly with brake cleaner. Inspect the cover for cracks, warping, or damage. If the magnetic drain plug is present, clean it thoroughly and inspect for excessive metal accumulation. Ensure both mating surfaces are completely clean, dry, and free of debris.
9. 9

   Install new gasket
   Position the new differential cover gasket on the cover or housing as designed (some gaskets have adhesive backing, others are dry-fit). Ensure gasket is properly aligned with all bolt holes and sealing surfaces. Do not use additional gasket sealant unless specifically required by Rivian service documentation.
10. 10

    Install differential cover
    Carefully position the differential cover with new gasket onto the housing, ensuring gasket remains properly seated. Start all bolts by hand, threading each bolt 2-3 turns to ensure proper alignment before tightening any bolt fully.
11. 11

    Torque differential cover bolts
    Tighten differential cover bolts in a crisscross star pattern, working from the center outward. Make multiple passes, gradually increasing torque. Without specific torque specifications available, use industry-standard specification for aluminum differential housing: approximately 15-20 ft-lbs for M8 bolts or 25-30 ft-lbs for M10 bolts. Verify bolt size before torquing. Final torque should be applied in a crisscross pattern to ensure even gasket compression.
12. 12

    Refill differential with gear oil
    Locate the differential fill plug (typically on upper or side of housing). Remove fill plug. Using a fluid transfer pump or funnel with extension hose, add 75W-90 GL-5 gear oil through fill hole. Add 1.5 quarts for front differential or 2.0 quarts for rear differential. Fill until oil reaches the bottom of the fill plug hole and begins to seep out. Reinstall and tighten fill plug.
13. 13

    Inspect for leaks
    Wipe down the entire differential cover area with clean shop towels. Wait 5 minutes and carefully inspect all areas around the cover gasket and fill plug for signs of leakage. If any seepage is observed, address before continuing.

Reassembly

1. Reinstall any underbody panels or skid plates removed during access
2. Reinstall wheel(s) and torque lug nuts to Rivian specification
3. Lower vehicle to ground
4. Reconnect 12V battery negative terminal
5. Exit Service Mode if it was enabled
6. Dispose of used gear oil at appropriate recycling facility

Verification

• Start vehicle and verify no warning lights related to drivetrain appear on instrument cluster
• Test drive vehicle at low speed in a safe area, making gentle turns in both directions to circulate gear oil
• After test drive, re-inspect differential cover for any signs of leakage
• Check gear oil level at fill plug after test drive to ensure proper fill level is maintained
• Monitor for any unusual noises from differential during initial operation

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