This procedure covers the removal and replacement of the front differential assembly on a 2022 Rivian EDV 500 dual motor AWD electric delivery vehicle.

Warnings

Tools required

Parts

• Front differential assembly (if replacing complete unit) × 1 — Use OEM specification
• Front differential drain plug gasket × 1 — Use OEM specification
• Front differential fill plug gasket × 1 — Use OEM specification
• Differential mounting bolts/hardware (if corroded) × 1 — Use OEM specification
• Axle shaft seals × 2 — Use OEM specification
• Drive unit electrical connector seals × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Verify high voltage system is powered down using manufacturer procedures
3. Disconnect 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
4. Disable high voltage system using service disconnect located in rear compartment
5. Verify zero voltage at front drive unit using appropriate high voltage test equipment
6. Lock out/tag out high voltage system per facility safety procedures
7. Raise vehicle on lift and support securely on jack stands at manufacturer designated lift points
8. Remove both front wheels
9. Place drain pan beneath front differential
10. Document or photograph electrical connector orientations and coolant line routing before disassembly

Procedure

1. 1

   Drain front differential fluid
   Locate the drain plug on the bottom of the front differential housing. Clean the area around the drain plug. Using the appropriate socket, remove the drain plug and allow all gear oil to drain completely into the drain pan. Inspect the drained fluid for metal particles or unusual debris that may indicate internal damage. Remove the fill plug to allow better drainage and airflow.
2. 2

   Disconnect cooling system lines
   Locate the coolant lines connected to the front drive motor/differential assembly. Note that this system uses dedicated EV motor coolant, not engine coolant. Using appropriate line disconnect tools, carefully detach the coolant supply and return lines from the drive unit. Have additional drain pans ready as coolant will drain from the lines. Cap or plug the coolant lines immediately to prevent contamination and further fluid loss.
3. 3

   Remove front axle shafts
   Remove the axle shaft retaining hardware at the wheel hub on both sides. Using a pry bar or axle puller, carefully separate the CV axle shafts from the differential output flanges. Support the axle shafts and secure them out of the way using mechanics wire or zip ties. Do not allow the CV joints to hang unsupported as this can damage the boots or joints. Inspect CV boots for damage during removal.
4. 4

   Disconnect electrical connectors
   Locate all electrical connectors on the front drive motor assembly. This typically includes the high voltage power connector, motor resolver/encoder connector, and temperature sensor connectors. Verify zero voltage one final time. Carefully unlock and disconnect each connector, noting their positions. Inspect connector seals and pins for any damage or corrosion. Secure connectors away from the work area.
5. 5

   Remove differential mounting brackets
   Locate and remove any support brackets, heat shields, or protective covers attached to the front differential assembly. These may be secured with multiple bolts of varying sizes. Use a wire brush to clean bolt threads if corrosion is present. Keep all hardware organized by location for reassembly.
6. 6

   Support the differential assembly
   Position a transmission jack or differential holding fixture beneath the front differential/motor assembly. Adjust the fixture to make contact with the differential housing and secure it with straps or chains. Raise the jack slightly to take the weight of the assembly off the mounting points, but do not lift the unit yet. Ensure the jack is stable and properly positioned to balance the weight.
7. 7

   Remove primary mounting bolts
   Locate the main differential mounting bolts that secure the assembly to the front subframe or chassis. There are typically multiple large bolts on the top and sides of the housing. Using a breaker bar and appropriate sockets, remove these bolts in a cross pattern to avoid binding. Keep track of bolt lengths and positions as they may vary. Support the assembly with the jack as you remove the final bolts.
8. 8

   Remove differential assembly
   With all mounting hardware removed and the assembly supported on the jack, carefully lower the front differential/motor unit. Guide it away from any remaining brackets or interference points. The assembly is heavy (typically 150-200 lbs), so maintain control at all times. Once lowered sufficiently, carefully maneuver it out from under the vehicle. Inspect the mounting points on the vehicle for damage or wear.
9. 9

   Inspect and prepare for installation
   If installing a replacement differential, transfer any necessary brackets, sensors, or fittings from the old unit to the new one. Clean all mounting surfaces on the vehicle using a wire brush and solvent. Inspect the axle seals in the differential outputs and replace if damaged or worn. Apply a thin coat of gear oil to new seals before installation. Verify all electrical connectors on the replacement unit are in good condition.
10. 10

    Install differential assembly
    Position the differential assembly on the transmission jack and carefully raise it into position beneath the vehicle. Align the mounting points with the subframe or chassis mounting locations. This may require minor adjustments to the jack position. Guide coolant line and electrical connector locations through their respective openings. Once aligned, start all mounting bolts by hand before tightening.
11. 11

    Torque mounting hardware
    Tighten all differential mounting bolts in a cross pattern to ensure even clamping force. Since torque specifications are not available in the database, consult the Rivian service manual for exact values. Typically, main mounting bolts will require 80-120 ft-lb of torque, but verify before proceeding. Reinstall all support brackets and heat shields with their respective hardware.
12. 12

    Reconnect axle shafts
    Guide the CV axle shafts back into the differential output flanges, ensuring proper seating. Install the axle shaft retaining hardware and tighten to specification per service manual. Verify that both axle shafts are fully engaged and seated properly by attempting to pull them outward. Check that CV boots are not twisted or damaged during installation.
13. 13

    Reconnect cooling system
    Remove the caps or plugs from the coolant lines. Inspect the O-rings or seals on the quick-connect fittings and replace if damaged. Reconnect the coolant supply and return lines to the drive unit, ensuring they click or lock into place properly. Verify secure connection by attempting to pull the lines apart. Double-check routing to ensure no interference with moving components.
14. 14

    Reconnect electrical connectors
    Reconnect all electrical connectors to the drive motor assembly in the reverse order of removal. Ensure each connector locks securely and seals are properly seated. Verify that connector retention clips are fully engaged. Inspect wire routing to ensure no chafing or interference points exist.
15. 15

    Refill differential with gear oil
    Using a gear oil pump, inject 1.5 quarts of 75W-90 GL-5 gear oil through the fill plug hole until oil begins to seep from the opening. Install the fill plug with a new gasket and tighten to specification. Install the drain plug with a new gasket and tighten to specification. Wipe away any spilled oil from the differential housing.

Reassembly

1. Reinstall both front wheels and tighten lug nuts to specification
2. Remove high voltage lockout/tagout devices
3. Reconnect 12V battery negative terminal
4. Bleed cooling system if necessary following manufacturer procedures to remove any air introduced during line disconnection
5. Lower vehicle from lift
6. Verify coolant level in the EV cooling system reservoir and top off if needed with EV Battery/Motor Coolant

Verification

• Perform a visual inspection of all connections, mounting points, and for any fluid leaks
• Enable high voltage system following manufacturer procedures
• Start vehicle and verify no warning lights or error codes related to the front drive system
• Using Rivian diagnostic software, verify front motor communication and function tests pass
• Perform a slow-speed test drive in a safe area, verifying smooth operation in both 2WD and AWD modes
• Check for unusual noises, vibrations, or handling issues during test drive
• After test drive, re-inspect differential and all connections for leaks
• Verify differential fluid level after test drive and top off if necessary
• Clear vehicle memory and perform any required drive unit relearn procedures using diagnostic software

More procedures for this vehicle