This procedure covers removal and replacement of the front axle seal on a 2023 Rivian EDV 500, including draining and refilling the front differential fluid.

Warnings

Tools required

Parts

• Front axle seal × 1 — Use OEM specification
• Axle nut (if damaged or torque-to-yield) × 1 — Use OEM specification
• Lower control arm ball joint nut (if equipped with torque-to-yield type) × 1 — Use OEM specification
• Differential fill plug gasket/seal × 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. Place wheel chocks behind rear wheels
3. Power down the vehicle completely using the center display, then disconnect the 12V battery negative terminal
4. If available in service documentation, perform high voltage disconnect procedure
5. Raise vehicle on lift or support securely on jack stands rated for vehicle weight
6. Remove front wheel on the side requiring seal replacement
7. Clean the work area around the front axle, hub, and differential to prevent contamination

Procedure

1. 1

   Mark and remove axle nut
   Use a paint marker or punch to mark the relationship between the axle nut and axle threads for torque reference. While an assistant applies the brake pedal, or with vehicle weight on the ground if preferred, use the breaker bar and appropriate socket to loosen and remove the front axle nut. Document the torque if possible during initial break-free.
2. 2

   Disconnect lower control arm
   Remove the lower control arm ball joint nut. Use a ball joint separator tool to disconnect the lower control arm from the steering knuckle. Avoid damaging the ball joint boot. Allow the control arm to hang freely or support with a bungee cord.
3. 3

   Separate axle from hub
   With the axle nut removed, the CV axle should be free from the wheel hub splines. If the axle is stuck in the hub, use a soft-faced mallet to tap the axle end while pulling the hub assembly outward. Some Rivian models may require removing the brake caliper bracket for clearance—if so, support the caliper with wire and do not let it hang by the brake hose.
4. 4

   Drain front differential fluid
   Position drain pan beneath the front differential. Locate and remove the differential drain plug (typically on the bottom or side of the differential housing). Allow all fluid to drain completely. Inspect the drained fluid for metal particles or contamination indicating internal wear.
5. 5

   Remove CV axle from differential
   Pull the wheel hub assembly outward to create clearance. Using a pry bar positioned against the differential housing (on a reinforced area, not the seal surface), carefully pry the inner CV joint from the differential. The axle is retained by a snap ring on the inner CV joint and should release with firm, steady pressure. Remove the axle assembly from the vehicle.
6. 6

   Remove old axle seal
   Inspect the differential seal bore for the seal orientation and depth. Using an axle seal puller or slide hammer with seal hooks, carefully extract the old seal from the differential housing. Work evenly around the seal to avoid damaging the bore. Remove any remnants of the old seal.
7. 7

   Clean and inspect seal bore
   Thoroughly clean the seal bore in the differential housing using brake cleaner and a lint-free cloth. Inspect the bore for scratches, burrs, or damage. Use a wire brush if necessary to remove any corrosion or debris. The seal surface must be smooth for proper sealing.
8. 8

   Inspect CV axle and snap ring
   Inspect the axle shaft seal surface for grooves, scoring, or rust that could damage the new seal. Clean the axle shaft with brake cleaner. Verify the snap ring on the inner CV joint is intact and properly seated in its groove. Replace if damaged or weak.
9. 9

   Install new axle seal
   Lightly coat the outer edge of the new seal with fresh gear oil. Position the seal squarely in the bore with the seal lip facing inward toward the differential fluid. Using an appropriately sized seal driver that contacts only the outer edge of the seal, tap the seal evenly into the bore until it is fully seated at the correct depth (typically flush or slightly recessed per OEM specification).
10. 10

    Reinstall CV axle into differential
    Coat the axle seal surface and inner CV joint splines lightly with fresh gear oil. Align the inner CV joint with the differential opening and push firmly until the snap ring clicks into place and seats in the differential side gear. Tug outward on the axle to verify it is locked in position.
11. 11

    Refill front differential
    Locate the differential fill plug (typically on the upper side of the housing). Remove the fill plug and install a fluid pump. Fill the front differential with 1.5 quarts of 75W-90 GL-5 gear oil, or until fluid reaches the bottom of the fill hole. Install a new fill plug gasket/seal if equipped and reinstall the fill plug. Reinstall the drain plug with new gasket if applicable.
12. 12

    Reconnect axle to hub
    Guide the outer CV axle shaft into the wheel hub, aligning the splines. Push the hub assembly inward and ensure the axle is fully seated through the hub bearing. Install the axle nut hand-tight to hold the assembly in position.
13. 13

    Reconnect lower control arm
    Raise the lower control arm ball joint into the steering knuckle. Install the ball joint nut and tighten. Without published torque specifications, tighten to the marked specification from disassembly or typical specification for this vehicle class (typically 75-100 ft-lbs for EV platforms). Install cotter pin if equipped.
14. 14

    Torque axle nut
    With the vehicle lowered to the ground or an assistant applying the brake pedal, torque the front axle nut. Without published specifications, refer to the torque reference made during removal and apply equivalent or greater torque (typically 150-200 ft-lbs for vehicles in this class). Verify the nut is fully seated against the washer and hub.
15. 15

    Reinstall wheel and final checks
    Reinstall the front wheel and torque lug nuts in a star pattern to manufacturer specification (typically 130-150 ft-lbs for this vehicle). Lower the vehicle to the ground. Reconnect the 12V battery negative terminal and restore vehicle power systems.

Reassembly

1. Ensure all fasteners have been properly tightened to specification or documented values
2. Verify no tools or parts are left in the wheel well or under the vehicle
3. Double-check that the differential drain and fill plugs are securely installed and not leaking

Verification

• Test drive the vehicle at low speed in a safe area, making gentle turns in both directions to verify no clicking, popping, or grinding noises from the front axle
• After test drive, raise the vehicle and inspect around the new axle seal for any signs of gear oil leakage
• Check differential fluid level through the fill plug—fluid should be at the bottom of the fill hole
• Verify proper operation of all vehicle systems after reconnecting the battery
• Re-torque the axle nut and lug nuts after 50-100 miles of driving
• Monitor for leaks during the first week of operation

More procedures for this vehicle