This procedure covers the removal and replacement of a front CV axle assembly on a 2023 Rivian EDV 500 commercial van with dual motor AWD drivetrain.

Warnings

Tools required

Parts

• Front CV axle assembly (specify left or right) × 1 — Use OEM specification
• CV axle hub nut × 1 — Use OEM specification
• Lower control arm ball joint pinch bolt × 1 — Use OEM specification
• Front differential sealing washer × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Perform high voltage system lockout according to Rivian service procedures and install lockout device
4. Loosen front wheel lug nuts while vehicle is on ground
5. Remove front wheel center cap and loosen but do not remove CV axle hub nut (vehicle must be on ground for this)
6. Raise vehicle with floor jack and support securely on jack stands at manufacturer-specified lift points
7. Remove front wheel completely
8. Position drain pan under front differential on the side being serviced

Procedure

1. 1

   Remove CV axle hub nut
   With the vehicle safely supported on jack stands, fully remove the previously loosened CV axle hub nut from the wheel hub. This nut is typically very tight and was loosened while the vehicle was on the ground to prevent hub rotation.
2. 2

   Disconnect wheel speed sensor
   Locate the ABS wheel speed sensor connector near the wheel hub or on the suspension tower. Press the locking tab and disconnect the electrical connector. Remove any clips securing the sensor wire to the suspension or brake components to provide clearance for axle removal.
3. 3

   Remove brake caliper
   Remove the two brake caliper mounting bolts and carefully lift the caliper off the rotor. Support the caliper with mechanics wire or a bungee cord to prevent stress on the brake hose. Do not allow the caliper to hang by the brake line.
4. 4

   Remove lower ball joint pinch bolt
   Locate the pinch bolt that secures the lower ball joint to the steering knuckle. Remove this bolt completely. You may need to use a pry bar to slightly spread the pinch joint to release the ball joint taper from the knuckle.
5. 5

   Separate lower control arm from knuckle
   Using a pry bar positioned between the lower control arm and the knuckle, carefully pry down to separate the ball joint from the knuckle. Be careful not to damage the ball joint boot. Once separated, push the lower control arm down and away from the knuckle to create clearance.
6. 6

   Push CV axle out of hub
   Pull the steering knuckle/hub assembly outward away from the vehicle. The outer CV joint splines should disengage from the wheel hub. If the axle is stuck in the hub, use a plastic dead blow hammer to tap on the end of the axle shaft, or use a hub puller if necessary. Do not strike the CV joint itself.
7. 7

   Support outer end of CV axle
   Once the outer splines are free from the hub, support the outer end of the CV axle with mechanics wire or have an assistant hold it to prevent the axle from dropping and damaging the inner CV joint or differential seal.
8. 8

   Remove inner CV joint from differential
   Position the drain pan directly under the inner CV joint. Using a pry bar positioned between the inner CV joint housing and the differential case, carefully pry the axle out of the differential. The axle should pop free with firm pressure. Be prepared for differential fluid to drain out. If the axle will not release, use a CV axle puller or slide hammer attached to the inner joint.
9. 9

   Remove CV axle assembly
   Carefully maneuver the complete CV axle assembly out from under the vehicle. Take care not to damage any surrounding components, brake lines, or wiring during removal. Inspect the removed axle for signs of boot damage, excessive play, or clicking noises that would confirm replacement is necessary.
10. 10

    Clean and inspect differential sealing surface
    Use a clean rag to wipe away any old differential fluid from around the differential output shaft opening. Inspect the differential seal for damage. Use a wire brush to clean the sealing surface where the CV axle enters the differential. Remove the old sealing washer from the inner CV joint.
11. 11

    Prepare new CV axle
    Remove the new CV axle from its packaging. Install a new sealing washer on the inner CV joint splines. Verify that the inner and outer CV joint boots are intact and properly secured with clamps. Apply a light coating of gear oil to the inner CV joint splines.
12. 12

    Install inner CV joint into differential
    Align the inner CV joint splines with the differential output shaft. Push the axle firmly into the differential until you feel the circlip engage with a distinct click or snap. Pull back on the axle to confirm it is fully seated and locked in place by the circlip.
13. 13

    Install outer CV joint into hub
    Guide the outer CV joint splines into the wheel hub while pulling the knuckle assembly outward. Ensure the splines fully engage into the hub. You may need to rotate the axle slightly to align the splines. Push the axle fully through the hub until it is seated.
14. 14

    Reconnect lower control arm to knuckle
    Lift the lower control arm and align the ball joint stud with the opening in the steering knuckle. Push the ball joint taper fully into the knuckle. Install a new pinch bolt and hand-tighten. Note: Final torque will be applied after vehicle is lowered.
15. 15

    Reinstall brake caliper and wheel speed sensor
    Remove the caliper from its support wire and position it over the brake rotor. Install the caliper mounting bolts. Reconnect the wheel speed sensor electrical connector and secure the sensor wire with any clips that were removed. Install a new CV axle hub nut and hand-tighten only at this stage.
16. 16

    Refill front differential
    Using 75W-90 GL-5 gear oil, refill the front differential to the proper level through the fill hole. The differential should take approximately 1.5 quarts total capacity. Fill until fluid begins to seep from the fill hole, then install and tighten the fill plug.

Reassembly

1. Reinstall the wheel and hand-tighten lug nuts in a star pattern
2. Lower vehicle until tire just touches the ground but most weight is still on jack stands
3. Torque CV axle hub nut to manufacturer specification while vehicle is partially supported (prevents hub rotation)
4. Torque lower ball joint pinch bolt to specification
5. Lower vehicle completely to the ground
6. Torque wheel lug nuts to specification in a star pattern
7. Reinstall wheel center cap
8. Remove high voltage lockout device and restore vehicle to operational status per Rivian procedures

Verification

• Test drive vehicle and listen for any clicking, popping, or grinding noises from the CV axle during acceleration, deceleration, and turning
• Verify no vibration is present at highway speeds
• Check for differential fluid leaks around the inner CV joint area after test drive
• Verify wheel speed sensor is functioning properly with no ABS warning lights
• Inspect CV axle boots for proper seating and any signs of damage or grease leakage
• Confirm hub nut is properly torqued and staked if applicable per manufacturer specifications

More procedures for this vehicle