This procedure covers the removal and installation of both front CV axles on the 2023 Rivian EDV 500 electric delivery van, including hub disconnection, differential separation, and reassembly.

Warnings

Tools required

Parts

• Front CV axle assembly (driver side) × 1 — Use OEM Rivian specification
• Front CV axle assembly (passenger side) × 1 — Use OEM Rivian specification
• Axle hub nut (36mm) × 2 — Use OEM specification - one-time use
• Differential seal ring × 2 — Use OEM specification
• Lower control arm ball joint nut × 2 — Check if reusable per OEM

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes for system discharge
3. Place wheel chocks behind rear wheels
4. With vehicle still on ground, break loose both front 36mm axle hub nuts (do not remove completely)
5. Loosen front wheel lug nuts while vehicle is on ground
6. Lift front of vehicle using approved lift points and secure on jack stands rated for vehicle weight
7. Remove both front wheels completely
8. Position drain pans under both sides of front differential
9. Take photos of axle routing and electrical connector positions for reference during reassembly

Procedure

1. 1

   Remove driver side axle hub nut and brake components
   Fully remove the 36mm axle hub nut that was previously loosened. Remove the brake caliper mounting bolts (typically 18mm) and secure the caliper to the suspension with mechanics wire without stressing the brake hose. Remove the brake rotor by pulling straight off the hub. If rotor is stuck, use rotor mounting screws or light tapping with rubber mallet.
2. 2

   Disconnect driver side lower ball joint
   Locate the lower control arm ball joint connection at the steering knuckle. Remove the ball joint castle nut (typically 19mm or 21mm). Use a ball joint separator tool to press the ball joint stud out of the knuckle. Do not use a pickle fork as this may damage the boot. Allow the lower control arm to drop down to create clearance.
3. 3

   Disconnect driver side outer CV joint from hub
   With the hub nut removed and lower ball joint disconnected, pull the steering knuckle/hub assembly outward away from the vehicle. The CV axle splines should slide out of the hub bearing. If stuck, use a CV axle puller or carefully tap the end of the axle with a brass drift. Do not damage the ABS sensor or tone ring on the back of the hub.
4. 4

   Remove driver side inner CV joint from differential
   Position drain pan directly under the driver side differential output. Using a pry bar positioned against the differential housing (not the axle shaft), carefully pry the inner CV joint out of the differential. The axle should pop out with the circlip releasing. Allow differential fluid to drain into pan. Remove the complete axle assembly from the vehicle. Inspect and remove the differential seal ring if it remained in the differential housing.
5. 5

   Repeat removal process for passenger side axle
   Repeat steps 1-4 for the passenger side CV axle: remove hub nut, remove brake caliper and rotor, disconnect lower ball joint, separate outer CV joint from hub, and pry inner CV joint from differential. Position drain pan to catch additional fluid loss. Remove complete passenger side axle assembly from vehicle.
6. 6

   Clean and inspect differential output splines
   With both axles removed, use a wire brush to clean the differential output spline areas. Inspect for damage, wear, or metal debris. Check that the differential seal surfaces are clean and free of burrs. Remove any old seal ring material from the differential housing.
7. 7

   Install new seal rings on replacement axles
   Install new differential seal rings onto the inner CV joint splines of both replacement axles. Ensure the seal rings are seated properly in their grooves. Apply a thin coat of 75W-90 gear oil to the seal rings and splines to aid installation.
8. 8

   Install driver side inner CV joint into differential
   Align the driver side replacement axle with the differential output. Push the inner CV joint firmly into the differential until you feel and hear the circlip snap into place. Give the axle a firm pull outward to verify the circlip is properly engaged. The axle should not pull out of the differential.
9. 9

   Install driver side outer CV joint into hub
   Maneuver the outer end of the driver side axle into position. Pull the steering knuckle/hub assembly outward and align the CV axle splines with the hub bearing. Push the axle through the hub until the splines are fully engaged and the axle end is flush with or slightly protruding from the hub face.
10. 10

    Reconnect driver side lower ball joint
    Lift the lower control arm back up to the steering knuckle. Insert the ball joint stud into the knuckle bore. Install a new or reusable castle nut per OEM specification and tighten to proper torque. Install cotter pin if applicable. Do not over-torque as this can damage the ball joint.
11. 11

    Repeat installation for passenger side axle
    Repeat steps 8-10 for the passenger side: install inner CV joint into differential (verify circlip engagement), install outer CV joint into hub bearing, and reconnect lower ball joint to steering knuckle.
12. 12

    Reinstall brake components and hub nuts
    For both sides, reinstall the brake rotors onto the hubs. Remount the brake calipers and tighten caliper mounting bolts to specification. Install new 36mm axle hub nuts onto both CV axle ends and hand-tighten. Do not fully torque at this time.
13. 13

    Refill front differential with gear oil
    Locate the front differential fill plug. Using a fluid pump or squeeze bottle, refill the front differential with 1.5 quarts of 75W-90 GL-5 gear oil through the fill hole until fluid reaches the bottom of the fill hole threads. Reinstall and tighten the fill plug to specification.
14. 14

    Reinstall wheels and torque axle hub nuts
    Reinstall both front wheels and hand-tighten lug nuts. Lower the vehicle until the wheels just contact the ground but most weight is still on jack stands. Torque both 36mm axle hub nuts to manufacturer specification (typically 200-250 ft-lb, but verify with OEM documentation). Fully lower vehicle to ground and torque wheel lug nuts in star pattern to specification.
15. 15

    Reconnect battery and perform system checks
    Reconnect the 12V auxiliary battery negative terminal. Turn on the vehicle and check for any warning lights or fault codes on the instrument cluster. Test the electric power steering by turning the wheel lock-to-lock while stationary. Check for any unusual noises or vibrations.

Reassembly

1. Ensure both axle hub nuts are torqued to proper specification - these are critical safety fasteners
2. Verify front differential fluid level is correct and fill plug is secure
3. Double-check that all brake components are properly reinstalled and caliper bolts are tight
4. Confirm lower ball joint nuts are properly torqued and cotter pins installed if applicable
5. Inspect under vehicle for any tools or parts left behind before test drive

Verification

• Test drive the vehicle at low speed in a safe area, making full left and right turns to verify no clicking, popping, or binding from CV joints
• Check for any vibration at various speeds that could indicate improper axle installation or imbalanced components
• Verify no differential fluid leaks are present after test drive - inspect both inner CV joint areas
• Confirm electric power steering functions normally with no binding or unusual noises
• Scan vehicle for any drivetrain fault codes using appropriate diagnostic tool
• If available, perform Rivian-required calibration procedures using manufacturer software or at Rivian service center

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