This procedure covers the removal and replacement of the rear differential assembly on a 2023 Rivian EDV 500 electric delivery van with dual motor AWD configuration.

Warnings

Tools required

Parts

• Rear differential assembly (if replacing complete unit) × 1 — Use OEM specification
• Differential mounting bolts × 1 — Use OEM specification
• Driveshaft bolts (if applicable) × 1 — Use OEM specification
• Differential gasket or RTV sealant × 1 — Use OEM specification
• Crush washers for drain/fill plugs × 2 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks at front wheels
3. Access the 12V battery disconnect switch in the front compartment and disconnect per Rivian service manual
4. Verify high voltage system is isolated using diagnostic software
5. Raise vehicle on lift ensuring proper lift point contact per manufacturer specifications
6. Remove both rear wheels
7. Allow differential to cool if vehicle was recently driven
8. Take photos of all electrical connectors and routing for reference during reassembly

Procedure

1. 1

   Drain rear differential fluid
   Place drain pan beneath rear differential. Locate and remove the differential drain plug (typically on bottom of housing). Allow all gear oil to drain completely. Once drained, reinstall drain plug with new crush washer finger tight for now to prevent contamination during disassembly.
2. 2

   Disconnect electrical connectors
   Locate all electrical connectors on the rear differential assembly including motor power cables, temperature sensors, and speed sensors. Release connector locks and carefully disconnect each connector. Use caution with high voltage connector interlocks - they must be fully disengaged before unplugging. Secure connectors away from work area.
3. 3

   Remove rear axle halfshafts
   Remove the bolts securing both rear halfshafts to the differential output flanges. You may need to rotate the halfshafts to access all bolts. Once bolts are removed, carefully pull halfshafts away from differential and secure them to the suspension or frame using wire or zip ties to prevent damage. Do not allow halfshafts to hang unsupported.
4. 4

   Disconnect coolant lines
   The rear drive unit has coolant lines for motor cooling. Place drain pan beneath connections. Release coolant line quick-connect fittings at the differential housing. Be prepared for coolant spillage. Cap or plug open lines immediately to prevent contamination and further fluid loss.
5. 5

   Support differential with transmission jack
   Position transmission jack or differential jack beneath the rear differential assembly. Raise jack until it makes contact and slightly supports the weight of the differential. Ensure jack is centered and stable. Use a block of wood or transmission jack adapter to protect the differential housing.
6. 6

   Remove differential mounting bolts
   Locate all differential mounting bolts that secure the assembly to the rear subframe. There are typically multiple mounting points including front and rear mounts. Remove these bolts while supporting the differential with the jack. Keep track of bolt locations as they may be different lengths.
7. 7

   Lower and remove differential assembly
   With all mounting bolts removed and all connections disconnected, carefully lower the transmission jack to remove the differential assembly from the vehicle. Guide it clear of the subframe and suspension components. You may need to angle or rotate the assembly slightly to clear the vehicle. Have an assistant help guide the unit if possible.
8. 8

   Inspect mounting points and connections
   With the differential removed, inspect all mounting points on the subframe for damage, cracks, or wear. Check condition of mounting bushings if equipped. Inspect coolant line fittings and electrical connectors in the vehicle for damage. Clean mounting surfaces of any old gasket material or debris.
9. 9

   Position new or serviced differential
   Place the replacement or serviced differential assembly onto the transmission jack. Carefully raise it into position, aligning mounting points with the subframe. This may require multiple attempts to achieve proper alignment. Ensure no wiring or coolant lines are pinched during installation.
10. 10

    Install differential mounting bolts
    Install all differential mounting bolts hand-tight initially. Once all bolts are started, tighten them in a cross pattern to ensure even loading. Note: Specific torque specifications are not available in the database - consult Rivian service documentation for proper torque values for mounting bolts.
11. 11

    Reconnect coolant lines
    Reconnect coolant lines to the differential assembly. Ensure quick-connect fittings are fully seated and locked. Tug gently on each line to verify secure connection. Check that coolant hoses are properly routed and not kinked or stretched.
12. 12

    Reinstall rear axle halfshafts
    Align rear halfshafts with differential output flanges. Install halfshaft bolts and tighten in a star pattern. Note: Specific torque specifications are not available in the database - consult Rivian service documentation for proper torque values. Ensure halfshafts are fully seated before tightening.
13. 13

    Reconnect electrical connectors
    Reconnect all electrical connectors to the differential assembly in reverse order of removal. Ensure high voltage connectors are fully seated and interlocks are engaged properly. Verify all connector locks are engaged. Route wiring per reference photos taken during disassembly.
14. 14

    Fill differential with gear oil
    Remove fill plug from differential housing. Using a fluid pump, fill differential with 2.0 quarts of 75W-90 GL-5 gear oil through the fill hole. Oil should reach the bottom of the fill hole when properly filled. Install fill plug with new crush washer and tighten per specifications.
15. 15

    Reinstall wheels and perform system checks
    Reinstall both rear wheels and torque lug nuts to specification. Lower vehicle to ground. Reconnect 12V battery. Using Rivian diagnostic software, clear any fault codes and perform rear drive unit initialization procedure. Check for proper operation of rear motor and verify no leaks are present.

Reassembly

1. Ensure all electrical connectors are properly seated and locked
2. Verify all mounting bolts are tightened to specification
3. Confirm differential fluid level is correct at operating temperature
4. Route all wiring and coolant lines per factory specifications to avoid interference with suspension travel
5. Perform complete visual inspection of work area before final vehicle lowering

Verification

• Use Rivian diagnostic software to verify rear drive unit communication and no fault codes present
• Perform test drive at various speeds to confirm proper operation and no unusual noises
• Check for gear oil leaks at drain plug, fill plug, and halfshaft seals after test drive
• Verify coolant level in reservoir has not dropped indicating leaks in motor cooling system
• Confirm both rear wheels are receiving power during acceleration
• Re-check all mounting bolt torques after initial test drive

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