This procedure drains and refills the front differential fluid on the 2023 Rivian EDV 500 dual motor AWD electric delivery van, requiring vehicle lifting and access to the front differential assembly.

Warnings

Tools required

Parts

• Front differential drain plug washer × 1 — Use OEM specification
• Front differential fill plug washer × 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. Place wheel chocks behind rear wheels
3. Connect Rivian diagnostic tool and place vehicle into Service Mode following manufacturer protocol
4. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes for system capacitor discharge
5. Lift vehicle using approved lift points specified in service manual and support on jack stands
6. Remove front skid plate or underbody panels to access front differential assembly
7. Clean exterior of front differential housing with degreaser to prevent contamination during service
8. Verify front differential identification tag matches service records

Procedure

1. 1

   Locate differential fill and drain plugs
   Identify the front differential assembly mounted behind the front motor unit. Locate the fill plug on the upper side of the differential housing and the drain plug on the lower rear portion of the housing. Note the orientation and access limitations imposed by nearby drive unit components and cooling lines.
2. 2

   Loosen fill plug first
   Before draining, loosen the fill plug first using the appropriate hex socket (typically 17mm or 19mm). This ensures you can refill the differential after draining. If the fill plug is seized or damaged, stop and address this issue before proceeding. Remove fill plug completely and inspect the sealing washer for damage.
3. 3

   Position drain pan and remove drain plug
   Position a drain pan with at least 3-quart capacity directly beneath the differential drain plug. Using the appropriate hex socket, carefully loosen the drain plug. As the plug is removed, fluid will begin flowing immediately. Remove the drain plug completely and allow fluid to drain fully, which may take 10-15 minutes. Inspect the drain plug magnetic tip for metal particles.
4. 4

   Inspect drained fluid condition
   Examine the drained fluid for color, consistency, and contamination. Normal used gear oil will be dark brown with minor metallic particles. Excessive metal debris, milky appearance (water contamination), or burnt odor indicates potential internal damage requiring further inspection. Document fluid condition for service records.
5. 5

   Clean and inspect drain plug
   Clean the drain plug threads and magnetic tip thoroughly with solvent and a lint-free cloth. Inspect the plug threads for damage or wear. Examine the sealing washer and replace if crushed, damaged, or if this is a repeat service interval. Clean the drain hole threads on the differential housing.
6. 6

   Install drain plug with new washer
   Install a new drain plug sealing washer onto the drain plug. Thread the drain plug into the differential housing by hand to ensure proper thread engagement. Torque the drain plug to manufacturer specification using a torque wrench. Without specific torque values available, apply moderate torque following standard differential drain plug specifications for aluminum housings (typically 25-35 ft-lb), avoiding over-tightening which can strip aluminum threads.
7. 7

   Prepare fluid pump and new gear oil
   Prepare the fluid pump with clean hose attachment. Have 1.5 quarts of 75W-90 GL-5 gear oil ready. Ensure the gear oil meets Rivian specifications and is suitable for electric vehicle differential applications. Verify the oil is at room temperature or slightly warm for easier pumping.
8. 8

   Fill front differential to specification
   Insert the fluid pump hose into the fill hole. Slowly pump 75W-90 GL-5 gear oil into the differential. Fill until oil begins to seep from the fill hole opening, indicating proper fill level. The front differential capacity is approximately 1.5 quarts. Allow a few moments for oil to settle and top off if level drops below the fill hole.
9. 9

   Install fill plug with new washer
   Wipe any excess gear oil from around the fill hole. Install a new fill plug sealing washer onto the fill plug. Thread the fill plug in by hand, then torque to manufacturer specification using a torque wrench. Apply the same torque guideline as the drain plug, ensuring a proper seal without over-tightening.
10. 10

    Clean differential housing exterior
    Thoroughly clean any spilled gear oil from the differential housing, suspension components, and underbody panels using degreaser and clean rags. This prevents dirt accumulation and allows for easy leak detection during post-service inspection.
11. 11

    Reinstall underbody protection
    Reinstall the front skid plate and any underbody panels that were removed for access. Ensure all fasteners are properly torqued and panels are securely mounted. Verify no tools or rags were left in the work area.
12. 12

    Reconnect battery and exit Service Mode
    Lower the vehicle from jack stands to the ground. Reconnect the 12V auxiliary battery negative terminal. Using the Rivian diagnostic tool, properly exit Service Mode following manufacturer procedures. This will restore normal vehicle operation and re-enable drive systems.

Reassembly

1. Verify all drain and fill plugs are properly torqued and new washers were installed
2. Ensure all underbody panels and skid plates are securely fastened
3. Confirm no tools, rags, or parts were left under the vehicle
4. Verify 12V battery is reconnected and vehicle systems are operational

Verification

• Start vehicle and verify no warning lights or differential-related fault codes appear on the instrument cluster
• Using the Rivian diagnostic tool, check for any new drivetrain fault codes
• Test drive vehicle at low speed in a safe area, listening for unusual noises from the front differential during acceleration and deceleration
• After test drive, re-inspect differential fill and drain plugs for any signs of leakage
• Check for gear oil drips on the ground after vehicle has been parked for 10 minutes
• Document service in vehicle maintenance records including fluid condition observations and mileage

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