This procedure involves draining and refilling the front differential fluid on a 2022 Rivian EDV 500 electric delivery van, ensuring proper lubrication of the front drive unit.

Warnings

Tools required

Parts

• 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

1. Park the vehicle on a level surface and engage the parking brake
2. Ensure the vehicle is fully powered off and the key fob is removed from the cabin
3. Allow the vehicle to cool for at least 30 minutes if recently driven
4. Lift the vehicle using a properly rated lift or jack and support on jack stands
5. Verify the vehicle is stable and secure before working underneath
6. Remove the front underbody panels or skid plates if equipped to access the front drive unit

Procedure

1. 1

   Locate the front differential drain and fill plugs
   Identify the front drive unit housing beneath the vehicle. Locate the drain plug on the bottom of the differential housing and the fill plug on the side. Clean the area around both plugs with a wire brush and shop towels to prevent contamination.
2. 2

   Position drain pan
   Place a drain pan with at least 3 quart capacity directly beneath the front differential drain plug. Ensure the pan is positioned to catch all draining fluid.
3. 3

   Remove fill plug first
   Using the appropriate socket, carefully loosen and remove the fill plug from the side of the differential housing. This ensures you can refill the unit after draining. If the fill plug is seized or stripped, stop and address this issue before draining.
4. 4

   Remove drain plug and drain fluid
   Using the appropriate socket, carefully loosen the drain plug. Remove the plug slowly and allow the gear oil to drain completely into the pan. This may take 5-10 minutes. Inspect the drained fluid for metal particles, debris, or unusual discoloration which may indicate wear issues.
5. 5

   Clean and inspect drain plug
   Once fluid has fully drained, clean the drain plug with a shop towel. Inspect the magnetic portion of the plug for metal shavings or debris. Some fine metallic residue is normal, but excessive chunks indicate potential problems. Clean the drain plug threads and sealing surface thoroughly.
6. 6

   Install new drain plug washer
   Remove and discard the old crush washer from the drain plug. Install a new OEM drain plug washer onto the plug. Do not reuse the old washer as it will not seal properly.
7. 7

   Reinstall drain plug
   Thread the drain plug with new washer into the differential housing by hand to ensure proper thread engagement. Since no torque specification is available in the database, tighten the drain plug firmly using hand tools following OEM guidelines. Avoid over-tightening which can strip threads or damage the housing.
8. 8

   Prepare fill equipment
   Prepare the fluid pump or transfer syringe with fresh 75W-90 GL-5 gear oil. If using a pump, attach appropriate hose or adapter to reach the fill hole. Ensure the oil is at room temperature for easier pumping.
9. 9

   Fill the front differential
   Insert the pump nozzle or syringe into the fill hole. Slowly pump in fresh 75W-90 GL-5 gear oil until it begins to overflow from the fill hole opening. The front differential capacity is approximately 1.5 quarts. Fill until fluid reaches the bottom of the fill hole threads, indicating proper level.
10. 10

    Install new fill plug washer
    Remove and discard the old crush washer from the fill plug. Install a new OEM fill plug washer onto the plug.
11. 11

    Reinstall fill plug
    Clean the fill plug threads if needed. Thread the fill plug with new washer into the housing by hand. Since no torque specification is available in the database, tighten the fill plug firmly using hand tools following OEM guidelines.
12. 12

    Clean the work area
    Wipe down the differential housing and surrounding areas to remove any spilled gear oil. Check for proper sealing at both the drain and fill plugs by inspecting for leaks.
13. 13

    Reinstall underbody panels
    If removed, reinstall any front underbody panels or skid plates. Ensure all fasteners are properly secured.

Reassembly

1. Lower the vehicle from the lift or jack stands
2. Dispose of used gear oil properly at a recycling center or automotive facility
3. Record the service date and mileage in the vehicle maintenance log

Verification

• Start the vehicle and allow the drive system to initialize
• With the vehicle still on level ground, check underneath for any fluid leaks from the drain or fill plugs
• Test drive the vehicle at low speeds and listen for any unusual noises from the front differential area
• After a short test drive (5-10 minutes), re-inspect the drain and fill plugs for any signs of leakage
• Verify proper operation of the front drive unit during acceleration and regenerative braking

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