Ring and Pinion

This procedure covers the removal and installation of the ring and pinion gear set in the front or rear differential of a 2022 Rivian EDV 500 electric delivery van.

Warnings

Tools required

Parts

• Ring and pinion gear set (specify front or rear) × 1 — Use OEM specification
• Pinion bearing set (inner and outer) × 1 — Use OEM specification
• Carrier bearings (left and right) × 1 — Use OEM specification
• Pinion seal × 1 — Use OEM specification
• Pinion nut × 1 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Use OEM specification
• Pinion crush sleeve or shim pack × 1 — Use OEM specification
• Ring gear bolts × 10 — Use OEM specification
• Gear marking compound × 1 — Generic

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Disconnect the 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
2. Verify high-voltage system is de-energized following Rivian safety protocols
3. Raise vehicle on lift and secure on jack stands at manufacturer-specified lift points
4. Remove wheels from the axle being serviced (front or rear)
5. Place drain pan under differential and remove drain plug to drain gear oil completely
6. Allow differential to drain for at least 15 minutes
7. Mark driveshaft-to-flange orientation for reassembly
8. Photograph or document all electrical connectors and sensor positions before disconnection

Procedure

1. 1

   Remove differential assembly from vehicle
   Disconnect the driveshaft from the differential input flange. Remove brake calipers and secure them without hanging on brake lines. Disconnect ABS sensors and any differential-mounted sensors. Support differential assembly with transmission jack. Remove differential mounting bolts and carefully lower assembly from vehicle. Transport to clean workbench.
2. 2

   Remove differential cover and carrier assembly
   Remove all differential cover bolts and carefully separate cover from housing using plastic pry tools if necessary. Remove carrier bearing cap bolts and mark caps for correct reinstallation orientation. Install case spreader tool and carefully spread differential case just enough to remove carrier assembly (typically 0.010 inch maximum spread). Remove carrier assembly with ring gear attached.
3. 3

   Remove and measure old ring gear
   Mark the ring gear orientation to the carrier for reference. Remove ring gear bolts (note: these are left-hand thread on some differentials). Use soft-faced hammer to separate ring gear from carrier. Measure and record ring gear runout if reusing carrier. Clean all old thread locker from bolt holes and carrier mounting surface.
4. 4

   Remove pinion gear and bearings
   Mark pinion nut position relative to pinion shaft for reference. Use holding tool on pinion flange and remove pinion nut. Remove pinion flange using appropriate puller. Carefully tap pinion shaft out from rear of housing, catching inner bearing and pinion crush sleeve (or shims). Remove outer pinion bearing race from housing using bearing race puller. Remove inner bearing race from housing. Record original pinion depth shim thickness if applicable.
5. 5

   Inspect all components and housing
   Thoroughly inspect differential housing for cracks, scoring, or damage. Inspect carrier assembly for wear or damage. Clean all bearing bores and sealing surfaces in housing. Inspect bearing bores for damage or unusual wear patterns. If reusing carrier bearings, inspect for pitting, scoring, or noise when rotated. Replace any questionable components.
6. 6

   Install new pinion bearings and set pinion depth
   Press new inner and outer pinion bearing races into housing using appropriate bearing race driver. Install inner pinion bearing onto pinion shaft using press or bearing installer. Using pinion depth gauge tool set, determine correct pinion depth shim thickness. The pinion will have a variance number etched on it (+ or - value in thousandths) that must be factored into shim calculation. Install calculated shim behind inner bearing race. This is the most critical measurement for proper gear contact pattern.
7. 7

   Install pinion gear and set pinion bearing preload
   Install new pinion seal in housing using seal driver. Lubricate pinion seal lip with gear oil. Install outer pinion bearing onto pinion shaft. Install new crush sleeve (or calculated shim stack) onto pinion shaft. Install pinion assembly into housing. Install pinion flange and new pinion nut. Tighten pinion nut gradually while measuring rotational torque with inch-pound torque wrench. Target preload is typically 15-25 in-lbs for new bearings. Do not back off nut to reduce preload - if exceeded, crush sleeve must be replaced and process restarted.
8. 8

   Install new ring gear on carrier
   Clean carrier ring gear mounting surface thoroughly. Heat new ring gear to approximately 200°F to aid installation (use oven or heat gun, do not use torch). Align ring gear to carrier ensuring proper orientation. Install new ring gear bolts with thread locker and tighten in star pattern to prevent distortion. Allow ring gear to cool completely before proceeding.
9. 9

   Install carrier bearings and set backlash
   Press new carrier bearings onto carrier assembly using appropriate bearing installer. Install carrier assembly into housing. Install bearing caps in their original orientation. Install bearing adjusters or shims. Adjust carrier bearing preload and ring gear backlash using dial indicator. Typical backlash specification is 0.005-0.008 inches, but verify with gear set manufacturer specifications. Ensure backlash is consistent around entire ring gear (check at 4 points 90° apart).
10. 10

    Check gear tooth contact pattern
    Apply thin coat of gear marking compound to 8-10 ring gear teeth in different locations. Rotate pinion through several revolutions in both directions under light resistance. Examine contact pattern on ring gear teeth. Pattern should be centered on tooth face with approximately 50-60% coverage. Adjust pinion depth (if pattern is too high or low on tooth) or backlash (if pattern is too far toward toe or heel) as necessary. Repeat until proper pattern is achieved on both drive and coast sides.
11. 11

    Final assembly and seal installation
    Once gear pattern is correct, clean all gear marking compound from gears using solvent. Verify all bearing preloads and backlash one final time. Apply RTV sealant or install new gasket on differential cover mating surface. Install differential cover and torque bolts in star pattern. Install any sensors, brackets, or components removed from differential housing.
12. 12

    Reinstall differential in vehicle
    Using transmission jack, carefully lift differential assembly into position in vehicle. Install all differential mounting bolts and torque to specification. Reconnect driveshaft to flange in original orientation. Reinstall brake calipers and torque caliper bolts. Reconnect all electrical connectors and sensors. Install wheels and torque lug nuts to specification.
13. 13

    Fill differential with gear oil and final checks
    Fill differential with specified 75W-90 GL-5 gear oil through fill plug until oil begins to drip from fill hole (approximately 1.5 qt for front differential, 2.0 qt for rear). Install fill plug. Lower vehicle to ground. Reconnect 12V battery. Start vehicle and verify no warning lights related to drivetrain or ABS systems. Test drive vehicle at low speeds listening for any unusual noises from differential.

Reassembly

1. Ensure all fasteners are torqued to specification (consult service manual as no torque specs were provided in database)
2. Verify driveshaft is installed in original orientation to prevent driveline vibration
3. Double-check that all electrical connectors and sensors are properly reconnected
4. Confirm proper gear oil level after test drive and top off if necessary

Verification

• Test drive vehicle through full range of speeds, verifying smooth operation with no whining, howling, or clunking from differential
• Perform several acceleration and deceleration cycles to verify proper gear engagement under load
• Check for any gear oil leaks around differential cover, pinion seal, and axle seals after test drive
• Verify no ABS or drivetrain warning lights are illuminated on instrument cluster
• After 50-100 miles of driving, recheck differential oil level and inspect for leaks
• Listen for proper gear noise characteristics - new gears may have slight break-in noise that should diminish within 500 miles

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