Differential Rebuild - Rear

Complete disassembly, inspection, and rebuild of the rear differential assembly on a 2022 Rivian EDV 500, including bearing replacement, gear inspection, and reassembly with new seals.

Warnings

Tools required

Parts

• Rear differential rebuild kit (includes bearings, races, seals) × 1 — Use OEM specification
• Pinion seal × 1 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Use OEM specification
• Pinion nut × 1 — Use OEM specification - one-time use
• Ring gear bolts × 1 — Use OEM specification - one-time use
• Axle shaft seals × 2 — Use OEM specification
• Shim kit for pinion depth adjustment × 1 — Use OEM specification
• Crush sleeve or solid spacer (verify type) × 1 — Use OEM specification
• Shop towels and cleaning supplies × 1 — Generic

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Review Rivian high-voltage safety procedures and verify technician certification for EV work
2. Ensure vehicle is on level ground and parking brake is released
3. Place wheel chocks at front wheels
4. Disconnect 12V auxiliary battery negative terminal
5. Verify high-voltage system is de-energized per manufacturer procedures
6. Raise vehicle on lift to working height and support securely
7. Remove rear wheels and tires
8. Mark drive shaft and differential yoke orientation with paint or marker
9. Place drain pan under differential
10. Take detailed photographs of differential assembly from multiple angles for reference

Procedure

1. 1

   Drain differential fluid and remove cover
   Remove the differential drain plug if equipped, or remove the cover bolts in a crisscross pattern to drain fluid. Once drained, remove all cover bolts and carefully separate cover from housing. Clean mating surfaces thoroughly and inspect fluid for metal particles or contamination that may indicate gear damage.
2. 2

   Remove axle shafts
   Remove the axle shaft retaining bolts or clips at the differential side. Carefully extract both axle shafts from the differential housing, being careful not to damage the axle seals. Set axle shafts aside on clean surface. Inspect axle shaft splines for wear or damage.
3. 3

   Remove drive shaft and pinion yoke
   Remove the drive shaft mounting bolts at the differential yoke, following marked orientation. Remove drive shaft and support out of work area. Mark pinion yoke orientation to pinion shaft. Using a holding tool to prevent rotation, remove the pinion nut (this is a one-time use fastener). Use a suitable puller to remove the pinion yoke from the pinion shaft. Inspect yoke seal surface for wear.
4. 4

   Measure and record gear backlash and bearing preload
   Mount dial indicator to housing with tip on ring gear tooth at 90 degrees to tooth face. Rock ring gear back and forth while holding pinion stationary and record backlash at four equally spaced points around ring gear. Record these measurements for comparison during reassembly. Measure and record pinion bearing preload by rotating pinion with inch-pound torque wrench. These baseline measurements are critical for proper reassembly.
5. 5

   Remove differential carrier assembly
   Remove the differential carrier bearing cap bolts. Mark bearing caps for orientation (they are not interchangeable). Install differential spreader tool in housing and carefully spread housing just enough to remove carrier (typically 0.010 inch maximum - do not over-spread). Remove carrier assembly with ring gear attached. Remove and keep all shims, marking their original location (pinion side vs ring gear side).
6. 6

   Remove ring gear and disassemble carrier
   Mark ring gear orientation to carrier. Remove ring gear bolts (one-time use fasteners) and separate ring gear from carrier using soft mallet if necessary. Drive out differential pinion shaft roll pin. Remove pinion shaft, pinion gears, side gears, and thrust washers. Keep all components organized and inspect for wear, scoring, or damage. Measure all clearances and compare to specifications.
7. 7

   Remove and inspect pinion assembly
   Support pinion gear from inside housing and tap pinion shaft out through front of housing with soft mallet. Remove pinion, crush sleeve (or solid spacer), inner bearing, and shim from housing. Remove and discard pinion seal. Press rear bearing from pinion shaft and remove rear bearing shim. Thoroughly inspect all bearing surfaces, gear teeth, and pinion for wear, pitting, scoring, or damage. Any damage to gears requires replacement of matched ring and pinion set.
8. 8

   Remove and inspect carrier bearings and races
   Using bearing puller, remove carrier bearings from differential carrier. Remove bearing races from housing using race puller or punch and hammer. Remove pinion bearing races from housing. Clean all bearing bores thoroughly. Inspect all bearing surfaces, races, and rollers for pitting, wear, or damage. Replace any questionable bearings as part of rebuild kit.
9. 9

   Clean and inspect all components
   Thoroughly clean differential housing, carrier, gears, and all components with parts cleaner and compressed air. Inspect housing for cracks, especially around bearing bores and mounting areas. Inspect all gear teeth on ring gear, pinion, side gears, and pinion gears for wear patterns, pitting, scoring, or chipping. Inspect splines on all shafts. Any significant damage requires replacement of matched gear sets.
10. 10

    Install new pinion bearings and determine pinion depth
    Press new pinion bearing races into housing, ensuring they are fully seated. Install rear pinion bearing on pinion shaft using press. Use pinion depth setting gauge tool and master gauge blocks to determine correct shim thickness for proper pinion depth. This is a critical measurement that affects gear contact pattern. Install calculated shim on pinion shaft, then press front bearing onto shaft. Verify pinion depth measurement with gauge tool.
11. 11

    Install pinion assembly into housing
    Install new pinion seal into housing using seal driver, ensuring proper depth and alignment. Lubricate seal lip with gear oil. Install pinion shaft with bearings into housing along with new crush sleeve (or solid spacer per OEM specification). Install pinion yoke, aligning marks made during disassembly. Install new pinion nut and tighten gradually while measuring rotating torque with inch-pound torque wrench. Tighten to achieve specified pinion bearing preload per factory specifications (typically 15-25 in-lbs for new bearings). Do not back off nut - if preload is exceeded, assembly must be disassembled and crush sleeve replaced.
12. 12

    Reassemble differential carrier
    Install side gears and thrust washers into carrier. Install pinion gears with thrust washers and rotate into position. Install pinion shaft through carrier and gears, aligning hole for roll pin. Install new roll pin to secure pinion shaft. Verify all gears rotate smoothly with proper clearances. Press new carrier bearings onto carrier hubs, ensuring proper seating.
13. 13

    Install ring gear on carrier
    Clean ring gear and carrier mating surfaces thoroughly. Align ring gear to carrier using marks made during disassembly (or per manufacturer runout specifications if installing new). Install new ring gear bolts with thread locking compound and tighten in star pattern to proper specification. Verify ring gear runout with dial indicator (should be less than 0.003 inch typically).
14. 14

    Install carrier assembly and set backlash
    Install original shims on carrier bearing hubs as starting point. Spread housing slightly with spreader tool (maximum 0.010 inch). Install carrier assembly into housing. Install bearing caps in original positions with marks aligned. Install cap bolts finger tight. Remove spreader tool. Transfer shims between left and right sides as needed to achieve proper ring gear backlash (typically 0.005-0.008 inch) while maintaining proper carrier bearing preload. Tighten bearing cap bolts to specification once correct shim combination is determined.
15. 15

    Check gear contact pattern and final adjustments
    Apply thin coat of gear marking compound to ring gear teeth. Rotate pinion through several revolutions in both directions with light resistance on ring gear. Examine contact pattern on ring gear teeth. Pattern should be centered on tooth face. Adjust pinion depth shim if pattern is too high or low on tooth. Adjust backlash if pattern is too far toward toe or heel of tooth. Repeat marking and adjustment until proper pattern is achieved. Clean all marking compound from gears thoroughly before final assembly.
16. 16

    Install axle seals and reassemble housing
    Drive new axle shaft seals into housing using proper size seal driver, ensuring seals are square and at proper depth. Apply thin bead of RTV silicone to differential cover or install new gasket per OEM specification. Install cover and tighten bolts in star pattern to proper specification. Allow RTV to cure per manufacturer instructions before filling with fluid.
17. 17

    Fill differential and complete reassembly
    Fill differential with 2.0 quarts of 75W-90 GL-5 gear oil through fill hole. Install and tighten fill plug. Reinstall axle shafts with new retaining hardware. Install drive shaft to yoke, aligning marks made during disassembly. Apply thread locking compound to drive shaft bolts and tighten to specification. Install rear wheels and tires. Lower vehicle.

Reassembly

1. All shim selections and adjustments must be made using precise measurements and factory specifications
2. All one-time use fasteners (pinion nut, ring gear bolts) must be replaced with new components
3. Bearing preload and gear backlash must be within factory specifications to prevent premature failure
4. Gear contact pattern must be verified and properly centered before final assembly
5. All sealing surfaces must be clean and free of old gasket material or RTV
6. Thread locking compound must be applied to specified fasteners per manufacturer requirements

Verification

• Verify no fluid leaks from pinion seal, axle seals, or differential cover after initial fill
• Rotate pinion by hand to verify smooth operation with no binding or excessive noise
• Check that ring gear backlash is within specification at multiple points around gear
• Verify pinion bearing preload is within specification using inch-pound torque wrench
• Test drive vehicle and verify no abnormal noise, vibration, or whining from differential under various load conditions
• Re-check differential fluid level after test drive and verify no leaks
• Inspect for proper operation in both forward and reverse with normal and hard acceleration
• After 100-500 miles, inspect differential for leaks and consider fluid change to remove break-in particles per manufacturer recommendation

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