This procedure covers the removal and replacement of the outer CV boot on a 2023 Rivian EDV 500 dual motor AWD electric delivery van, requiring disassembly of the front suspension and halfshaft components.

Warnings

Tools required

Parts

• Outer CV boot kit with clamps and grease × 1 — Use OEM specification
• Axle nut (single use) × 1 — Use OEM specification
• Lower ball joint cotter pin × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Power off the vehicle completely using the infotainment system
3. Disconnect the 12V auxiliary battery negative terminal located in the front storage compartment
4. Loosen the front wheel lug nuts and the 36mm axle nut while the vehicle is still on the ground with the wheel installed (do not remove yet)
5. Raise the front of the vehicle and support on jack stands at the manufacturer-specified lift points
6. Remove the front wheel on the side requiring CV boot replacement
7. Place a drain pan under the front differential to catch any fluid that may escape

Procedure

1. 1

   Remove axle nut and wheel speed sensor
   With the wheel removed, fully remove the 36mm axle nut that was previously loosened. Remove any dust cap or cover if present. Disconnect the wheel speed sensor electrical connector and remove the sensor mounting bolt to move the sensor away from the work area. Secure the sensor to prevent damage.
2. 2

   Disconnect lower ball joint
   Remove the cotter pin from the lower ball joint castle nut. Remove the castle nut using an 18mm or 19mm socket. Use a ball joint separator tool to press the ball joint stud out of the steering knuckle. Do not use a pickle fork if you intend to reuse the ball joint boot. Apply penetrating oil if the joint is seized.
3. 3

   Separate halfshaft from hub
   With the lower ball joint disconnected, pull the knuckle assembly outward to separate the halfshaft splines from the hub bearing. You may need to tap the end of the halfshaft with a soft face hammer or use a brass drift to break it free. Do not damage the threads on the halfshaft end.
4. 4

   Remove halfshaft from differential
   Using a pry bar positioned against the differential case and the inner CV joint, carefully pry the halfshaft out of the differential. Apply steady force to overcome the snap ring retention. Be prepared for gear oil to drain from the differential. Once the shaft is free, support it and carefully remove it from under the vehicle.
5. 5

   Secure halfshaft in work area
   Place the removed halfshaft on a clean workbench or secure it in a vise with soft jaws clamping the shaft (not the CV joints). Position the outer CV joint for easy access. Clean the exterior of the joint and surrounding area with degreaser and a wire brush.
6. 6

   Remove damaged outer CV boot
   Using CV boot clamp pliers or cutting pliers, cut and remove both the large and small clamps securing the outer CV boot. Slide the damaged boot toward the center of the shaft to expose the outer CV joint. Wipe away all old grease from the joint, housing, and shaft using clean rags.
7. 7

   Inspect CV joint components
   Carefully inspect the CV joint ball bearings, races, and cage for any signs of wear, pitting, corrosion, or damage. Rotate the joint through its full range of motion and feel for roughness or binding. If the joint shows any damage, the entire halfshaft assembly should be replaced rather than just the boot. Clean all components thoroughly if reusing.
8. 8

   Install new outer CV boot
   Slide the new small clamp onto the halfshaft first, followed by the new CV boot (small end first). Position the small end of the boot in the groove on the halfshaft. Install the small clamp and crimp it securely using CV boot clamp pliers, ensuring it is tight and properly seated in the boot groove.
9. 9

   Pack CV joint with grease
   Apply the CV joint grease supplied in the boot kit. Pack grease into the CV joint housing, working it between all ball bearings and races. Use the full amount of grease provided in the kit (typically 4-6 oz for outer joint). Ensure the joint is completely filled and all components are coated.
10. 10

    Secure outer boot clamp
    Slide the large end of the CV boot over the outer CV joint housing and seat it in the designated groove. Ensure the boot is not twisted. Install the large clamp over the boot. Before tightening, adjust the boot to the proper length/position as specified (usually with the joint at ride height angle). Crimp the large clamp securely, ensuring a tight seal to prevent grease leakage and contamination entry.
11. 11

    Reinstall halfshaft into differential
    Position the halfshaft under the vehicle. Align the inner CV joint splines with the differential side gear. Push the halfshaft firmly into the differential until you feel and hear the snap ring engage with a positive click. Tug on the shaft to verify it is fully seated and retained.
12. 12

    Install halfshaft into hub and reconnect ball joint
    Guide the outer end of the halfshaft through the hub bearing, aligning the splines. You may need to rotate the hub to align the splines properly. Push the knuckle inward and insert the lower ball joint stud into the knuckle. Install the castle nut and tighten to specification (torque spec not provided - follow manufacturer service manual). Install a new cotter pin through the castle nut and ball joint stud.
13. 13

    Install wheel speed sensor and axle nut
    Reinstall the wheel speed sensor into its mounting location and tighten the mounting bolt. Reconnect the electrical connector, ensuring it clicks into place. Install the new axle nut onto the halfshaft threads and hand-tighten. The final torque will be applied with the wheel installed and vehicle on the ground.
14. 14

    Check and refill differential fluid
    Locate the front differential fill plug. Check the fluid level by removing the fill plug - fluid should be at the bottom of the fill hole. Add 75W-90 GL-5 gear oil as needed to bring the level to specification (approximately 1.5 quarts total capacity). Replace the fill plug and tighten to specification.

Reassembly

1. Reinstall the wheel and hand-tighten the lug nuts in a star pattern
2. Lower the vehicle to the ground
3. Torque the 36mm axle nut to manufacturer specification (typically 170-200 ft-lbs for similar vehicles, but verify in service manual)
4. Torque the wheel lug nuts to specification in a star pattern (typically 140-150 ft-lbs)
5. Reconnect the 12V auxiliary battery negative terminal
6. Power on the vehicle and verify no warning lights related to wheel speed sensors or drivetrain are present

Verification

• Test drive the vehicle at low speed in a safe area, making full lock turns in both directions to verify the CV joint operates smoothly without binding, clicking, or noise
• Inspect the new CV boot for any signs of grease leakage or improper clamp installation
• Verify the wheel speed sensor is functioning by checking for ABS/traction control warning lights on the dashboard
• Re-check the front differential fluid level after test drive to ensure no additional fluid loss occurred
• Perform a final inspection under the vehicle to confirm all fasteners are tight and components are properly secured

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