This procedure replaces the rear differential fluid on a 2022 Rivian EDV 500 electric delivery van to maintain proper lubrication of the rear drive unit.

Warnings

Tools required

Parts

• Rear differential drain plug washer/gasket × 1 — Use OEM specification
• Rear differential fill plug washer/gasket × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks in front of front wheels
3. Power off the vehicle completely using the center display
4. Wait at least 5 minutes for high-voltage system to discharge
5. Open the hood and disconnect the negative terminal of the 12V battery
6. If vehicle was recently driven, allow differential to cool for at least 30 minutes
7. Raise vehicle using lift or floor jack and secure on jack stands at manufacturer-specified lift points
8. Verify vehicle stability before working underneath
9. Remove rear wheels to improve access if needed

Procedure

1. 1

   Locate rear differential service plugs
   Position yourself under the rear of the vehicle. Locate the rear drive unit (differential) housing. Identify the drain plug on the bottom of the housing and the fill plug on the side of the housing. Clean the area around both plugs with a wire brush and shop towels to prevent contamination.
2. 2

   Remove fill plug first
   Using the appropriate socket, carefully loosen and remove the fill plug first. This ensures you can refill the differential after draining. If the fill plug is seized and cannot be removed, do not proceed with draining. Inspect the fill plug washer/gasket for damage and have replacement ready.
3. 3

   Position drain pan and remove drain plug
   Place the drain pan directly under the differential drain plug with at least 3 quarts capacity. Using the appropriate socket, slowly loosen the drain plug. Remove the plug completely and allow all gear oil to drain into the pan. The oil flow may be slow initially. Allow at least 10-15 minutes for complete drainage.
4. 4

   Inspect drain plug and housing
   While oil is draining, inspect the drain plug for metal shavings or debris on the magnetic tip (if equipped). Minor fine particles are normal, but large chunks or excessive material may indicate internal wear. Inspect the drain plug threads and washer sealing surface. Check the drain hole for damage or cross-threading.
5. 5

   Clean and prepare drain plug
   Thoroughly clean the drain plug with shop towels, removing all old oil and debris. Clean the magnetic tip if equipped. Remove and discard the old washer/gasket. Install a new drain plug washer/gasket. Clean the sealing surface around the drain hole on the differential housing.
6. 6

   Install drain plug
   Thread the drain plug with new washer by hand to ensure proper thread engagement. Once hand-tight, use a torque wrench to tighten to the manufacturer's specification. Since no torque specification is provided in the database, tighten firmly but avoid over-torquing which can strip aluminum housing threads (typical specification is 20-30 ft-lbs for this type of plug).
7. 7

   Prepare new gear oil
   Verify you have 75W-90 GL-5 gear oil meeting Rivian specifications. You will need 2.0 quarts. If oil is cold, it may be thick and difficult to pump. Room temperature oil flows more easily. Prepare your fluid transfer pump or squeeze bottle with extension hose.
8. 8

   Fill rear differential
   Insert the pump hose or squeeze bottle nozzle into the fill hole. Slowly pump or squeeze gear oil into the differential. Fill until oil begins to run out of the fill hole, indicating the proper level has been reached. The differential should take approximately 2.0 quarts. Allow excess oil to drain back to proper level.
9. 9

   Install fill plug
   Clean any spilled oil from around the fill hole. Remove and discard the old fill plug washer/gasket. Install a new washer/gasket on the fill plug. Thread the fill plug by hand until hand-tight, then use a torque wrench to tighten to specification. Since no torque specification is provided, tighten firmly but avoid over-torquing.
10. 10

    Clean and inspect for leaks
    Wipe down the entire differential housing with shop towels to remove any spilled gear oil. Inspect both drain and fill plugs for proper seating and initial leak check. Clean any oil from surrounding components and the vehicle undercarriage.
11. 11

    Reinstall wheels and lower vehicle
    If wheels were removed, reinstall them and torque lug nuts to specification in a star pattern. Carefully raise vehicle slightly to remove jack stands. Lower vehicle completely to the ground.
12. 12

    Reconnect battery and power on
    Reconnect the negative terminal of the 12V battery. Ensure connection is tight and secure. Power on the vehicle using the center display. Check for any warning lights or messages related to the drivetrain.

Reassembly

1. Ensure both drain and fill plugs are tightened to specification with new washers installed
2. Verify all tools and materials are removed from under the vehicle
3. Dispose of used gear oil properly at a recycling facility or auto parts store

Verification

• Start the vehicle and verify no drivetrain warning lights are present on the instrument cluster
• With the vehicle on level ground, check underneath for any signs of gear oil leakage around the drain and fill plugs
• Take a short test drive (1-2 miles) to circulate the new gear oil through the differential
• After test drive, re-inspect the rear differential for leaks with the vehicle on level ground
• If equipped with Rivian diagnostic software, check for any stored fault codes related to the rear drive unit
• Monitor for any unusual noises from the rear differential during normal driving over the next few days

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