This procedure covers the replacement of the differential cover gasket on a 2023 Rivian EDV 500, including draining and refilling the differential fluid for both front and rear differentials.

Warnings

Tools required

Parts

• Differential cover gasket (front) × 1 — Use OEM specification
• Differential cover gasket (rear) × 1 — Use OEM specification
• Differential cover bolts (if reuse not recommended) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil (Front Differential) — 1.5 qt
• 75W-90 GL-5 Gear Oil (Rear Differential) — 2 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind wheels that will remain on ground
3. Disconnect 12V battery negative terminal and wait 5 minutes
4. Raise vehicle using lift or jack stands at designated lift points
5. Remove wheels if necessary for access to differential covers
6. Verify differential fluid has cooled to safe temperature
7. Locate differential cover(s) requiring gasket replacement
8. Clean exterior of differential cover and surrounding area to prevent contamination

Procedure

1. 1

   Position drain pan and remove fill plug
   Position drain pan beneath the differential cover. Locate and remove the differential fill plug first using appropriate socket. This ensures the fill plug is not seized before draining fluid. Front differential fill plug capacity is 1.5 quarts, rear is 2.0 quarts.
2. 2

   Remove differential cover bolts
   Using appropriate socket, loosen differential cover bolts in a crisscross pattern to prevent cover warping. Remove all bolts except the top two, loosening them but leaving them partially threaded.
3. 3

   Drain differential fluid
   Carefully remove the final two bolts while supporting the differential cover. Allow the cover to drop slightly and let fluid drain completely into drain pan. This may take 10-15 minutes. Once drained, fully remove cover and set aside.
   ⚠Fluid will pour out rapidly once cover is loosened. Ensure drain pan is properly positioned.
4. 4

   Clean differential housing mating surface
   Remove old gasket material from differential housing mating surface using scraper or gasket removal tool. Take care not to gouge or scratch the aluminum housing surface. Clean surface thoroughly with brake cleaner and lint-free towels until completely free of old gasket material, oil residue, and debris.
5. 5

   Inspect differential components
   Inspect visible differential gears and bearings for abnormal wear, metal particles, or damage. Check magnet (if equipped) on differential cover for excessive metal debris. Normal operation will show fine metallic dust, but large particles indicate potential internal damage requiring further inspection.
6. 6

   Clean differential cover
   Thoroughly clean the differential cover, removing all old gasket material from the mating surface. Clean the magnet (if equipped). Use brake cleaner and lint-free towels. Ensure both mating surfaces are completely clean and dry before proceeding.
7. 7

   Install new gasket on differential cover
   Position new differential cover gasket onto the cover. Some gaskets may have adhesive backing to hold in place. If gasket does not have adhesive, a thin bead of RTV silicone may be used to hold gasket in position if specified by Rivian service procedures. Ensure gasket is properly aligned with all bolt holes.
8. 8

   Install differential cover
   Carefully position differential cover with gasket onto differential housing, ensuring gasket remains properly seated. Start all bolts by hand to ensure proper thread engagement before tightening any bolts.
9. 9

   Torque differential cover bolts
   Tighten differential cover bolts in a crisscross pattern to ensure even gasket compression. Since manufacturer torque specifications are not available in the database, consult Rivian service information for proper torque values. Typical differential cover bolts require 15-25 ft-lb, but verify with OEM specifications before tightening.
10. 10

    Refill differential with gear oil
    Using fluid pump or syringe, refill differential through fill hole with appropriate amount of 75W-90 GL-5 gear oil. Front differential requires 1.5 quarts, rear differential requires 2.0 quarts. Fill until fluid reaches bottom of fill hole and begins to seep out, indicating proper level.
11. 11

    Install fill plug and check for leaks
    Clean fill plug threads and install fill plug. Torque to manufacturer specification (consult Rivian service information). Wipe down entire differential cover area with clean towel to remove any residual oil, making it easier to spot leaks during verification.

Reassembly

1. Reinstall wheels if removed and torque lug nuts to specification
2. Lower vehicle to ground
3. Reconnect 12V battery negative terminal
4. Properly dispose of used differential fluid at appropriate recycling facility

Verification

• Start vehicle and verify no warning lights related to drivetrain systems
• Test drive vehicle for 10-15 minutes, including turns in both directions to distribute fluid
• Re-inspect differential cover area for any signs of fluid leakage while vehicle is still warm
• Check differential fluid level through fill plug after test drive - fluid should be at bottom edge of fill hole
• Perform final inspection after 50-100 miles of driving and check for leaks

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