ev-motor

Electric Drive Motor R&R

for 2022 Rivian EDV 500 Dual Motor AWD (EDV) · AWD

Editorial review:Chris Hackleman — Master Technician · 20+ years · Jeff Moore — Master Lexus & Toyota Mechanic · 20+ years

Difficulty

Expert

Time

9.0 h

Tools

Steps

✓Expert-verified. Personally reviewed and approved by OLP's master technicians (Chris Hackleman & Jeff Moore — 20+ years each). Always follow the vehicle's factory service information and torque specs.

This procedure covers the removal and replacement of the electric drive motor on a 2022 Rivian EDV 500 with dual motor AWD configuration.

Warnings

⚠️High voltage system present. Lethal voltage remains in system even after 12V battery disconnect. Follow all high voltage lockout/tagout procedures before beginning work.

⚠️Verify zero voltage at motor terminals with CAT III rated multimeter before touching any high voltage components.

⚠️Only technicians trained and certified in high voltage electric vehicle systems should perform this procedure.

⚠Motor assembly weighs approximately 150-200 lbs. Use proper lifting equipment and techniques to prevent injury.

⚠Coolant may be hot if vehicle was recently operated. Allow cooling system to cool completely before draining.

ℹ️Document motor orientation, connector positions, and routing of all harnesses before disassembly for accurate reassembly.

Tools required

Rivian diagnostic software and compatible scan toolEssential

High voltage safety gloves (Class 0, 1000V rated)Essential

High voltage safety matEssential

Multimeter with CAT III 1000V ratingEssential

Vehicle lift or jack stands rated for EV weightEssential

Torque wrench set (10-250 Nm range)Essential

Electric coolant drain pan (minimum 5 gallon capacity)

Transmission jack or equivalent supportEssential

Pry bar set

Socket set (metric, 8mm-24mm)Essential

Breaker bar

Thread locker (medium strength)

Cable tie kit for securing harnesses

Parts

Electric drive motor assembly × 1 — Use OEM specification
Drive motor mounting gasket/seal × 1 — Use OEM specification
Motor coolant inlet/outlet O-rings × 2 — Use OEM specification
High voltage connector seals × 1 — Use OEM specification
Halfshaft seals (if damaged) × 2 — Use OEM specification

Fluids

EV Battery/Motor Coolant — 10 qt
EV Transmission Fluid — 10 qt

Preparation

Park vehicle on level surface and engage parking brake
Ensure vehicle has been off for minimum 30 minutes to allow high voltage system to discharge
Connect Rivian diagnostic software and place vehicle in service mode
Disconnect 12V auxiliary battery negative terminal
Don high voltage safety gloves and verify proper insulation rating
Remove underbody panels and skid plates to access motor compartment
Place high voltage safety mat under work area
Photograph all electrical connections and harness routing for reference

Procedure

1
High Voltage System Lockout
Using Rivian diagnostic software, initiate high voltage disconnect procedure. Follow on-screen prompts to safely disable the high voltage battery system. Install high voltage lockout device per manufacturer procedure. Apply lockout/tagout tags. Verify system is locked out by checking diagnostic software confirms zero high voltage present.
2
Verify High Voltage Isolation
Using CAT III 1000V rated multimeter, verify zero voltage between motor phase terminals and vehicle ground. Check voltage between all three motor phase terminals. Document readings - all should be zero volts. Do not proceed if any voltage is detected.
3
Drain Motor Cooling System
Position drain pan beneath motor cooling circuit drain plug. Open motor coolant drain valve and allow EV Battery/Motor Coolant to drain completely. Note approximate quantity drained for refill reference. Disconnect coolant inlet and outlet lines from motor housing. Cap open lines to prevent contamination. Remove and inspect coolant line O-rings for damage.
4
Disconnect High Voltage Power Cables
Remove high voltage connector protective covers. Wearing high voltage safety gloves, disconnect the three-phase power cables from motor terminals. Note cable positions and labeling (U, V, W phases). Secure cables away from work area using non-conductive ties. Install protective caps on motor terminals and cable ends.
5
Disconnect Low Voltage Connections
Disconnect motor resolver/encoder connector from motor housing. Disconnect motor temperature sensor connector. Disconnect any additional motor control module connectors. Label each connector with position reference. Secure all disconnected harnesses away from motor removal path using cable ties.
6
Remove Halfshafts
Mark halfshaft orientation to motor output flanges. Remove halfshaft mounting bolts on both sides of the motor being serviced. Support halfshafts with wire or mechanics wire to prevent damage to CV joints. Do not allow halfshafts to hang unsupported by their boots or joints.
7
Support Motor Assembly
Position transmission jack or equivalent support device beneath motor assembly. Adjust support to contact motor housing securely. Apply slight upward pressure to relieve weight from mounting points. Ensure motor is stable and properly balanced on support before proceeding.
8
Remove Motor Mounting Hardware
Remove motor-to-subframe mounting bolts. Work in cross pattern to prevent binding. Keep track of bolt locations as lengths may vary by position. Remove any support brackets or braces connected to motor housing. Carefully note positions of any shims or spacers for reinstallation.
9
Separate Motor from Drivetrain
If motor shares housing with reduction gear unit, carefully separate motor from transmission housing by removing interface bolts. Work slowly and check for any remaining connections. Use plastic pry tools if needed to break gasket seal - do not damage mating surfaces. Keep motor level during separation to prevent internal component damage.
10
Lower and Remove Motor
Slowly lower transmission jack while guiding motor clear of vehicle structure. Watch for any snagged harnesses or coolant lines. Rotate motor as needed to clear subframe and suspension components. Once clear, carefully move motor to clean work surface. Inspect motor mounting surfaces and sealing surfaces for damage.
11
Prepare New Motor for Installation
Remove shipping brackets and protective covers from replacement motor. Install new motor mounting gasket or seal onto motor housing mating surface. Install new O-rings on coolant inlet and outlet ports - lubricate with clean coolant. Verify resolver/encoder and sensor connections are accessible and undamaged. Compare new motor to removed unit to confirm correct replacement part.
12
Install Motor Assembly
Position new motor on transmission jack and raise into position beneath vehicle. Align motor with mounting points and drivetrain interface. Guide motor into position while watching for clearance issues. Align motor housing with transmission/reduction gear housing ensuring proper shaft engagement. If equipped with alignment dowels, ensure proper seating before installing bolts.
13
Install Mounting Hardware and Reconnect Halfshafts
Install motor-to-subframe mounting bolts and any support brackets. Tighten mounting bolts in cross pattern to ensure even seating. Reconnect halfshafts to motor output flanges matching orientation marks made during removal. Install halfshaft mounting bolts and tighten in star pattern. Remove transmission jack support once motor is fully secured.
14
Reconnect All Electrical Connections
Reconnect motor temperature sensor and resolver/encoder connectors. Reconnect motor control module connectors per labels and reference photos. Wearing high voltage safety gloves, reconnect three-phase power cables to correct motor terminals (U, V, W). Ensure high voltage connectors are fully seated and locked. Install high voltage connector protective covers. Verify all connections are secure and properly routed.
15
Reconnect Cooling System and Fill
Install new O-rings on coolant line connections. Reconnect coolant inlet and outlet lines to motor housing ensuring secure connection. Fill motor cooling circuit with specified EV Battery/Motor Coolant to proper level. Burp cooling system per manufacturer procedure to remove air pockets. Check for coolant leaks at all connections.

Reassembly

Reinstall underbody panels and skid plates with all fasteners
Reconnect 12V auxiliary battery negative terminal
Remove high voltage lockout device per manufacturer procedure
Clear service mode using Rivian diagnostic software
Verify all tools and parts have been removed from vehicle
Double-check all electrical connections are properly seated and locked

Verification

Using Rivian diagnostic software, perform motor relearn and initialization procedure
Check for diagnostic trouble codes and clear any installation-related codes
Verify motor resolver/encoder values are within specification using diagnostic software
Perform motor rotation test using diagnostic software to confirm proper operation in both directions
Check coolant level after system stabilizes and top off if necessary
Verify no coolant leaks at motor connections
Perform test drive to verify motor operates smoothly with no abnormal noise or vibration
Verify proper torque delivery and regenerative braking function
Confirm no warning lights or fault codes present after test drive
Document motor serial number and installation date in vehicle service records