This procedure covers the complete differential fluid change for both front and rear differentials on the 2023 Rivian EDV 500 dual motor AWD electric delivery van.

Warnings

Tools required

Parts

• Front differential drain plug gasket × 1 — Use OEM specification
• Front differential fill plug gasket × 1 — Use OEM specification
• Rear differential drain plug gasket × 1 — Use OEM specification
• Rear differential fill plug gasket × 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. Allow drivetrain to cool for minimum 2 hours if recently operated
3. Verify you have correct 75W-90 GL-5 gear oil specification - do NOT use fluids with friction modifiers unless specifically required by Rivian
4. Raise vehicle on lift or secure with jack stands at manufacturer-approved lift points
5. Remove underbody panels or skid plates as necessary to access front and rear differential drain and fill plugs
6. Inspect differential housings for signs of leaks, damage, or excessive contamination
7. Have drain pan, new gaskets, and fill equipment ready before opening any plugs

Procedure

1. 1

   Locate and identify front differential service plugs
   Position yourself under the front of the vehicle. Locate the front differential housing integrated with the front electric motor assembly. Identify the fill plug (typically located on upper side of differential) and drain plug (located at lowest point of differential housing). Clean the area around both plugs with wire brush and rag to prevent contamination during service.
2. 2

   Remove front differential fill plug first
   Using appropriate hex bit or socket, loosen and remove the front differential fill plug. Always remove the fill plug BEFORE the drain plug to ensure you can refill the differential. If fill plug is seized or cannot be removed, do not proceed with draining. Inspect fill plug gasket and set aside with new replacement gasket ready.
3. 3

   Drain front differential fluid
   Position drain pan under front differential drain plug. Remove drain plug and allow fluid to drain completely (approximately 10-15 minutes). Inspect drained fluid for metal particles, discoloration, or contamination. Excessive metallic debris may indicate component wear requiring further inspection. Remove and discard old drain plug gasket.
   ⚠Gear oil may be hot and will flow rapidly when drain plug is removed
4. 4

   Reinstall front differential drain plug
   Clean drain plug threads and sealing surface with lint-free rag. Install new gasket on drain plug. Thread drain plug into housing by hand to avoid cross-threading, then tighten to specification. Without manufacturer torque specification, tighten drain plug firmly but do not over-torque aluminum housing (approximately 25-30 ft-lb typical for this application, but verify with service data).
5. 5

   Refill front differential
   Using fluid pump or suction gun, add 75W-90 GL-5 gear oil through fill hole. Fill until fluid level reaches bottom of fill plug opening (fluid should just begin to seep out). Install new gasket on fill plug and reinstall plug, tightening to appropriate specification. Wipe away any spilled fluid from differential housing.
6. 6

   Locate and identify rear differential service plugs
   Move to rear of vehicle and locate the rear differential housing integrated with the rear electric motor assembly. Identify the fill plug (typically on upper or side surface) and drain plug (at lowest point of housing). Clean area around both plugs thoroughly with wire brush and rag.
7. 7

   Remove rear differential fill plug first
   Using appropriate hex bit or socket, loosen and remove the rear differential fill plug before removing drain plug. Verify fill plug can be removed and reinstalled before proceeding. Inspect fill plug gasket and prepare new gasket for reinstallation.
8. 8

   Drain rear differential fluid
   Position drain pan under rear differential drain plug (note: rear differential capacity is 2.0 quarts, larger than front). Remove drain plug and allow complete drainage for 10-15 minutes. Inspect fluid condition for metal particles or contamination. Remove and discard old drain plug gasket.
   ⚠Ensure drain pan has adequate capacity for 2 quarts of fluid
9. 9

   Reinstall rear differential drain plug
   Clean drain plug threads and sealing surface thoroughly. Install new gasket on drain plug. Hand-thread drain plug into housing, then tighten appropriately. Without manufacturer specification, use consistent torque with front differential plug (approximately 25-30 ft-lb typical, but verify with service data).
10. 10

    Refill rear differential
    Using fluid pump, add 2.0 quarts of 75W-90 GL-5 gear oil through rear differential fill opening. Fill until fluid reaches bottom of fill plug opening and begins to seep out. Install new gasket on fill plug and reinstall, tightening to specification. Clean any spilled fluid from housing exterior.
11. 11

    Reinstall underbody panels
    Reinstall any skid plates, underbody panels, or protective covers that were removed for access. Ensure all fasteners are properly secured and no tools or materials are left in underbody area.

Reassembly

1. Verify all drain and fill plugs are properly tightened and not leaking
2. Confirm all underbody panels and protective covers are reinstalled
3. Double-check that no tools, rags, or containers remain under vehicle
4. Lower vehicle to ground carefully

Verification

• Start vehicle and allow to idle briefly, then engage drive and reverse gears to circulate new differential fluid
• Perform short test drive (2-3 miles) at various speeds, making turns in both directions to fully distribute gear oil
• Re-raise vehicle and inspect both differentials for any signs of leakage around drain and fill plugs
• Check fluid levels again after test drive - top off if necessary through fill plugs
• Monitor for any unusual noises from front or rear axles during subsequent driving
• Record service date and mileage for maintenance tracking

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