This procedure covers the removal and replacement of the front differential assembly on the 2023 Rivian EDV 500 electric delivery van, including drivetrain disconnection and fluid service.

Warnings

Tools required

Parts

• Front differential assembly × 1 — Use OEM Rivian part
• Front differential mounting bolts × 1 — Replace if damaged or corroded
• CV axle seals × 2 — Use OEM specification
• Differential drain plug washer × 1 — Use OEM specification
• Differential fill plug washer × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level ground and apply parking brake securely
2. Place wheel chocks behind rear wheels
3. Power down the vehicle completely using the main power-down sequence in the center display
4. Wait at least 5 minutes after power-down before proceeding
5. Disconnect the 12V low-voltage battery negative terminal
6. Raise the front of the vehicle and secure on jack stands at manufacturer-recommended lift points
7. Remove both front wheels
8. Place drain pan under front differential
9. Allow differential to cool if vehicle was recently driven (minimum 30 minutes)

Procedure

1. 1

   Drain front differential fluid
   Locate the drain plug on the bottom of the front differential housing. Clean the area around the drain plug with a wire brush. Using the appropriate socket, remove the drain plug and allow all gear oil to drain completely into the drain pan. This will take 5-10 minutes. Inspect the drained fluid for metal particles or contamination. Remove the fill plug on the side of the differential to allow complete drainage and venting.
2. 2

   Disconnect front driveshafts
   Mark the orientation of both front CV axle shafts to the differential output flanges. Remove the bolts securing each CV axle inner joint to the differential output flanges. There are typically 6 bolts per side. Support the CV axles with wire or zip ties to prevent them from hanging and damaging the boots. Do not allow the axles to drop or extend fully.
3. 3

   Disconnect electrical connectors
   Locate and disconnect any electrical connectors attached to the front differential assembly. On the EDV 500, this typically includes speed sensors and possibly temperature sensors mounted to the differential housing. Press the locking tabs and carefully pull connectors straight out. Do not pull on wires. Mark or photograph connector positions.
4. 4

   Remove differential breather hose
   Locate the breather hose attached to the top or side of the differential housing. This hose allows pressure equalization during operation. Carefully disconnect the breather hose from its mounting point on the differential. Trace the hose to ensure it is free from any clips or ties along its length.
5. 5

   Support differential with transmission jack
   Position a transmission jack or differential jack under the center of the front differential assembly. Raise the jack until it just contacts the differential housing. Secure the differential to the jack using a strap or chain to prevent it from shifting or falling during removal. The differential should be stable but not under load yet.
6. 6

   Remove front differential mounting bolts
   Locate all mounting bolts securing the front differential to the subframe or crossmember. There are typically 4-6 large mounting bolts. Using a breaker bar or impact wrench, remove these bolts while supporting the differential with the jack. Remove bolts in a crossing pattern to prevent binding. Keep track of bolt locations as they may be different lengths.
7. 7

   Remove front differential assembly
   With all mounting bolts removed, carefully lower the transmission jack to separate the differential from the vehicle. Guide the differential down and away from the vehicle, watching for any remaining connections or obstructions. The output shafts will slide out of the CV axle joints. Have an assistant help guide the differential if needed. Once clear, lower the jack and move the differential to a workbench.
8. 8

   Inspect mounting points and seals
   With the differential removed, inspect the mounting surfaces on the subframe for damage, cracks, or corrosion. Clean all mounting surfaces with a wire brush. Inspect the differential mounting bushings or isolators for wear or damage. Check the CV axle seals in the differential housing for leaks or damage and replace if necessary.
9. 9

   Prepare new or replacement differential
   If installing a new differential, remove any shipping plugs or covers. Verify the new differential matches the removed unit in terms of mounting points and output shaft configuration. Install new CV axle seals if not already installed. Ensure the drain and fill plugs are installed with new washers.
10. 10

    Install differential assembly
    Position the differential on the transmission jack and raise it into position under the vehicle. Align the differential mounting points with the subframe mounting holes. Guide the CV axle shafts into the differential output seals carefully to avoid damaging the seals. This may require rotation of the axle shafts or differential. Once aligned, start all mounting bolts by hand before tightening.
11. 11

    Torque differential mounting bolts
    Tighten the differential mounting bolts in a crossing pattern to ensure even loading. Since specific torque values are not provided in the database, follow the specifications in the Rivian service manual. Typically these bolts require 80-120 ft-lbs. Verify all bolts are fully seated and torqued properly. Remove the transmission jack once the differential is securely mounted.
12. 12

    Reconnect driveshafts
    Align the CV axle inner joints with the differential output flanges according to the marks made during disassembly. Install all mounting bolts and tighten in a star pattern. Torque to specification per the service manual (typically 40-60 ft-lbs for CV axle bolts). Verify the axles rotate freely without binding.
13. 13

    Reconnect electrical and breather connections
    Reconnect all electrical connectors to the differential, ensuring they click into place securely. Verify each connector is fully seated and locked. Reconnect the breather hose to the differential housing, ensuring it is routed properly and secured with any clips along its path. The breather must not be kinked or restricted.
14. 14

    Fill differential with gear oil
    Using a fluid pump or syringe, fill the differential through the fill plug hole with 1.5 quarts of 75W-90 GL-5 gear oil. Fill until oil begins to drip from the fill hole, indicating proper level. Apply thread sealant to the fill plug threads and install the fill plug with a new washer. Install the drain plug with a new washer and torque to specification. Wipe away any spilled oil.
15. 15

    Final inspection and reinstall wheels
    Perform a final visual inspection of all connections, bolts, and fluid levels. Verify no tools or parts were left in the work area. Reinstall both front wheels and torque lug nuts to specification (typically 140-150 ft-lbs for the EDV 500). Lower the vehicle from jack stands. Reconnect the 12V battery negative terminal.

Reassembly

1. Torque all fasteners to manufacturer specifications using a calibrated torque wrench
2. Ensure all electrical connectors are fully seated and locked in place
3. Verify the differential breather hose is properly routed and not kinked
4. Double-check that the differential is filled to the proper level with the correct gear oil
5. Confirm all CV axle connections are secure and properly aligned

Verification

• Start the vehicle and allow it to run through its self-check sequence. Verify no warning lights appear related to the drivetrain
• With the vehicle on the ground, turn the steering wheel fully left and right while stationary to check for any binding or unusual noises from the CV axles
• Perform a slow test drive in a safe area, checking for proper AWD operation, unusual noises, or vibrations
• After the test drive, re-inspect the differential for any fluid leaks around the drain plug, fill plug, and output shaft seals
• Check that all mounting bolts remain tight after the test drive
• Verify proper AWD operation by monitoring the vehicle display for front motor engagement during acceleration

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