This procedure covers the removal and replacement of the inner CV boot on a 2023 Rivian EDV 500 dual motor AWD electric delivery van, requiring disassembly of the CV axle assembly.

Warnings

Tools required

Parts

• Inner CV boot kit (includes boot, clamps, and grease) × 1 — Use OEM Rivian specification
• CV axle snap ring (if damaged) × 1 — Use OEM specification
• Differential seal (recommended) × 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. Power down vehicle completely and wait 5 minutes for high voltage systems to discharge
3. Disconnect 12V battery negative terminal
4. Raise vehicle and secure on jack stands at manufacturer-specified lift points
5. Remove wheel and tire assembly on the side being serviced
6. Place drain pan under differential to catch any fluid spillage
7. Clean the work area around the CV axle and differential to prevent contamination

Procedure

1. 1

   Remove wheel speed sensor and brake components
   Disconnect the wheel speed sensor electrical connector. Remove the brake caliper mounting bolts and secure the caliper to the suspension with a wire or bungee cord without stressing the brake hose. Remove the brake rotor if necessary for clearance.
2. 2

   Remove axle nut
   Have an assistant apply the brake pedal or use a pry bar to prevent hub rotation. Remove and discard the axle nut. This is a single-use fastener on most applications and should not be reused.
   ⚠The axle nut is torqued to a very high value. Ensure proper tools and support are used to prevent injury.
3. 3

   Separate lower ball joint or control arm
   Remove the lower ball joint castle nut and use a ball joint separator tool to disconnect the lower control arm from the steering knuckle. Alternatively, remove the control arm mounting bolts if easier access is needed. Support the lower control arm to prevent suspension drop.
   ⚠Do not use a pickle fork or wedge tool that will damage the ball joint boot unless the ball joint is being replaced.
4. 4

   Remove outer tie rod end
   Remove the outer tie rod end castle nut and use a tie rod separator tool to disconnect the tie rod from the steering knuckle. This provides additional clearance for axle removal. Mark the tie rod position before removal to maintain alignment settings.
5. 5

   Remove CV axle from hub
   Push the CV axle shaft out of the wheel hub assembly. If the axle is stuck, use a brass drift and hammer to carefully tap it free from the hub splines. Do not damage the threads on the axle shaft.
6. 6

   Remove CV axle from differential
   Using a pry bar positioned against the differential housing and inner CV joint housing, carefully pry the axle assembly out of the differential. The axle will release with a snap as the snap ring disengages. Alternatively, use a slide hammer with axle puller attachment. Allow differential fluid to drain into the pan.
   ⚠Do not pry against the differential seal surface or aluminum housing as this can cause damage. Pry only against the CV joint housing.
7. 7

   Secure axle and cut old boot clamps
   Place the CV axle in a vise with soft jaws, clamping on the axle shaft only (never on the CV joint housing). Using CV boot clamp pliers or side cutters, cut and remove both clamps from the inner CV boot. Slide the damaged boot away from the joint.
8. 8

   Mark CV joint orientation and disassemble
   Before separating the joint, use a paint marker or scribe to mark the relationship between the inner CV joint housing, the tripod/spider assembly, and the axle shaft. Remove the snap ring that retains the tripod assembly on the axle shaft using snap ring pliers. Slide the tripod assembly off the axle shaft, keeping the needle bearings and rollers together if possible.
   ℹ️The tripod assembly is precisely balanced. Keep all components together and note their orientation to prevent vibration during reassembly.
9. 9

   Clean and inspect components
   Remove all old grease from the CV joint housing, tripod assembly, and axle shaft using degreaser and cleaning rags. Inspect the tripod needle bearings, rollers, and joint housing for wear, pitting, or damage. Check the axle shaft for wear at the snap ring groove and splines. If any components show significant wear, the entire CV axle should be replaced rather than just the boot.
   ℹ️Any scoring, pitting, or wear on CV joint components will cause premature failure even with a new boot.
10. 10

    Install new inner CV boot
    Slide the new small boot clamp and new CV boot onto the axle shaft from the inner end. Ensure the boot is positioned correctly on the axle shaft with the small end seated in the boot groove. Do not install the clamp yet.
11. 11

    Reinstall tripod assembly
    Align the tripod assembly with your alignment marks and slide it onto the axle shaft. The chamfered or numbered side typically faces the axle shaft. Install the snap ring in the groove, ensuring it is fully seated in the groove around its entire circumference. Verify the tripod cannot slide off the shaft.
12. 12

    Pack joint with grease and install boot
    Pack approximately half of the supplied CV grease into the inner CV joint housing. Install the tripod assembly into the housing, aligning your previous marks. Add the remaining grease around and over the tripod assembly. Slide the large end of the boot over the CV joint housing and seat it in the housing groove. Ensure the boot is not twisted.
    ℹ️Use only the grease supplied with the boot kit. Different grease types are not compatible and can cause premature boot and joint failure.
13. 13

    Equalize boot pressure and install clamps
    Before clamping, insert a small flat tool between the boot and housing to allow trapped air to escape and equalize the pressure. Remove the tool and install both boot clamps using the appropriate clamp installation tool. The small clamp secures the boot to the axle shaft, and the large clamp secures it to the CV joint housing. Ensure clamps are tight and properly seated.
    ℹ️Proper boot pressure equalization prevents boot ballooning or collapsing during operation, which causes premature failure.
14. 14

    Reinstall CV axle into differential
    Clean the differential seal area and install a new differential seal if recommended. Install a new snap ring on the inner CV joint stub shaft if the original was damaged. Align the CV axle with the differential opening and push firmly until the snap ring engages with a audible click. Tug on the axle to verify it is fully seated and locked in place.
15. 15

    Reinstall CV axle into hub and reassemble suspension
    Guide the outer CV shaft through the hub assembly and ensure the splines are fully engaged. Reinstall the outer tie rod end to the steering knuckle. Reconnect the lower ball joint or control arm to the steering knuckle. Install all fasteners but do not fully torque until vehicle is at normal ride height. Install a new axle nut on the CV shaft and torque to specification (specification not provided in database - consult service manual). Reconnect the wheel speed sensor. Reinstall brake rotor and caliper.
    ℹ️Suspension and steering components should be torqued at normal ride height with the vehicle weight on the wheels to prevent premature bushing failure.

Reassembly

1. Refill the differential with 75W-90 GL-5 gear oil to the proper level using the fill plug (1.5 quarts for front differential, 2.0 quarts for rear differential)
2. Reinstall wheel and tire assembly and torque lug nuts to specification in a star pattern
3. Lower vehicle to ground and torque all suspension and steering fasteners to specification at normal ride height
4. Reconnect 12V battery negative terminal
5. Power up vehicle and verify no warning lights or error codes related to wheel speed sensors or drivetrain

Verification

• Test drive the vehicle at various speeds and listen for any clicking, popping, or grinding noises from the CV joint area
• Perform full lock turns in both directions to verify no binding or unusual noises
• Inspect the new CV boot after test drive for any signs of grease leakage or improper installation
• Verify wheel speed sensor is functioning properly with no ABS or traction control warning lights
• Check differential fluid level after test drive and top off if necessary
• Re-inspect all fasteners for proper torque and inspect the boot clamps to ensure they remain properly seated

More procedures for this vehicle