This procedure replaces the differential fluid in both front and rear differentials of the 2022 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Front differential drain plug gasket/washer × 1 — Use OEM specification
• Front differential fill plug gasket/washer × 1 — Use OEM specification
• Rear differential drain plug gasket/washer × 1 — Use OEM specification
• Rear differential fill plug gasket/washer × 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. Ensure vehicle has been off for at least 30 minutes to allow differentials to cool
3. Place wheel chocks behind wheels that will remain on ground
4. Lift vehicle using approved lift points or jack and support on rated jack stands at all four corners
5. Remove front and rear skid plates or underbody panels if equipped to access differential drain and fill plugs
6. Clean area around differential drain and fill plugs with brake cleaner and shop rags

Procedure

1. 1

   Locate front differential drain and fill plugs
   Position yourself under the front axle. Identify the front differential housing between the front wheels. Locate the drain plug on the bottom of the housing and the fill plug on the side or upper portion of the housing. Clean both plugs thoroughly with a wire brush and brake cleaner to prevent contamination.
2. 2

   Loosen front differential fill plug first
   Before draining, first loosen the fill plug to ensure you can refill the differential after draining. Use appropriate size socket to break the fill plug loose. If the fill plug is seized and cannot be removed, do not proceed with draining. Leave fill plug loosened but installed.
3. 3

   Drain front differential fluid
   Position drain pan under front differential drain plug. Remove the drain plug completely and allow old fluid to drain fully into pan. This may take 5-10 minutes. Inspect drained fluid for metal particles or contamination that might indicate differential damage. Remove and inspect drain plug gasket/washer.
4. 4

   Reinstall front differential drain plug
   Install new drain plug gasket/washer onto drain plug. Thread drain plug into differential housing by hand to avoid cross-threading. Tighten drain plug to manufacturer specification using torque wrench. Note: Torque specification not available in database - refer to service manual or contact Rivian service for proper torque value.
5. 5

   Refill front differential
   Remove fill plug completely. Using fluid pump or suction gun with hose attached, inject 1.5 quarts of 75W-90 GL-5 gear oil into the fill hole. Fill until fluid begins to seep out of fill hole, indicating proper level. Allow excess to drain back for 30 seconds.
6. 6

   Reinstall front differential fill plug
   Install new fill plug gasket/washer onto fill plug. Thread fill plug into differential housing by hand. Tighten fill plug to manufacturer specification using torque wrench. Wipe away any spilled fluid from differential housing exterior.
7. 7

   Locate rear differential drain and fill plugs
   Move to rear axle area. Identify the rear differential housing centered between the rear wheels. Locate the drain plug on the bottom of the housing and the fill plug on the side or upper portion. Clean both plugs thoroughly with wire brush and brake cleaner.
8. 8

   Loosen rear differential fill plug first
   Use appropriate socket to break the rear differential fill plug loose before draining. Verify the plug can be removed. If seized, do not proceed with draining. Leave fill plug loosened but installed.
9. 9

   Drain rear differential fluid
   Position drain pan under rear differential drain plug. Remove drain plug completely and allow old fluid to drain fully, which may take 5-10 minutes. Inspect drained fluid for metal particles, water contamination, or unusual odor. Remove and inspect drain plug gasket/washer for damage.
10. 10

    Reinstall rear differential drain plug
    Install new drain plug gasket/washer onto drain plug. Thread drain plug into differential housing by hand to prevent cross-threading. Tighten drain plug to manufacturer specification using torque wrench. Note: Torque specification not available in database - refer to service manual or contact Rivian service.
11. 11

    Refill rear differential
    Remove rear differential fill plug completely. Using fluid pump or suction gun, inject 2.0 quarts of 75W-90 GL-5 gear oil into the fill hole. Continue filling until fluid begins to seep from fill hole opening. Allow excess to drain back for 30 seconds to establish proper level.
12. 12

    Reinstall rear differential fill plug
    Install new fill plug gasket/washer onto fill plug. Hand thread fill plug into differential housing. Tighten fill plug to manufacturer specification using torque wrench. Clean any spilled fluid from differential housing and surrounding components.
13. 13

    Inspect for leaks
    Carefully inspect both front and rear differential drain and fill plugs for any signs of leakage. Wipe all plug areas clean and verify gaskets are properly seated. Check surrounding areas for any fluid drips.

Reassembly

1. Reinstall any underbody panels or skid plates that were removed for access
2. Lower vehicle to ground carefully
3. Remove wheel chocks
4. Properly dispose of used differential fluid at approved recycling facility

Verification

• Start vehicle and allow to idle for 1 minute, then shut off
• Test drive vehicle for approximately 5 miles including turns in both directions to circulate new fluid through differentials
• After test drive, raise vehicle and inspect both differentials for any signs of leakage around drain and fill plugs
• Check fluid level by briefly removing fill plugs - fluid should be at bottom edge of fill hole
• Monitor for any unusual noises from differentials during subsequent driving

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