Axle Seal - Rear

This procedure covers the removal and replacement of the rear axle seals on a 2023 Rivian EDV 500, including draining and refilling the rear differential fluid.

Warnings

Tools required

Parts

• Rear axle seal (driver side) × 1 — Use OEM specification
• Rear axle seal (passenger side) × 1 — Use OEM specification
• Differential drain plug seal/gasket × 1 — Use OEM specification
• Differential fill plug seal/gasket × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Ensure vehicle is on level ground and powered off completely
2. Disconnect 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
3. Raise vehicle on lift or secure on jack stands at manufacturer lift points
4. Remove both rear wheels
5. Place drain pan beneath rear differential housing
6. Clean area around differential drain and fill plugs to prevent contamination

Procedure

1. 1

   Drain rear differential fluid
   Locate the drain plug on the bottom of the rear differential housing. Using appropriate socket, carefully remove the drain plug and allow all fluid to drain completely into drain pan. This should yield approximately 2 quarts of fluid. Remove fill plug from side of differential to allow complete drainage and venting.
2. 2

   Remove rear brake calipers
   Remove brake caliper mounting bolts on both sides. Hang calipers from suspension components using caliper hangers or mechanics wire. Do not allow calipers to hang by brake hoses. Remove brake rotors if necessary for additional clearance.
3. 3

   Remove axle hub nuts
   Remove the center axle hub nuts from both rear wheels. These are large fasteners that may require significant torque to loosen. Mark the position of the axle relative to the hub for reassembly orientation if applicable.
4. 4

   Disconnect wheel speed sensors
   Disconnect the electrical connectors for both rear wheel speed sensors. Mark or photograph connections for proper reassembly. Secure wiring harnesses away from work area.
5. 5

   Separate CV axles from hubs
   Using appropriate CV axle puller or separator tool, separate the outer CV joint from the wheel hub on both sides. Support the axle to prevent damage to CV joint boots during removal.
6. 6

   Remove CV axles from differential
   Using pry bar or CV axle removal tool, carefully pry the inner CV joint from the differential housing on both sides. Mark left and right axles if they are side-specific. Support axles and move aside, being careful not to over-extend CV joints or damage boots. Expect residual gear oil to drain when axles are removed.
7. 7

   Remove old axle seals
   Using axle seal puller or slide hammer with appropriate attachment, carefully extract both rear axle seals from the differential housing. Take care not to damage the seal bore surface in the housing. Inspect bore for any scoring, pitting, or damage that would prevent proper seal seating.
8. 8

   Clean seal bores and inspect
   Thoroughly clean the seal bore surfaces in the differential housing using clean shop rags. Remove all old seal material, debris, and contamination. Inspect the axle seal surface on both CV axle shafts for wear, scoring, or damage. Replace axles if seal surfaces are damaged.
9. 9

   Install new axle seals
   Coat the outer diameter of the new axle seals with seal installation lubricant or clean gear oil. Using appropriate size seal driver from seal driver set, carefully drive new seals into differential housing until fully seated and flush with housing face. Ensure seals are installed square and not cocked. Coat the seal lips with clean gear oil.
10. 10

    Reinstall CV axles into differential
    Coat the axle seal contact surfaces on CV axle shafts with clean gear oil. Carefully align and insert the inner CV joints into the differential, ensuring they fully engage with the differential side gears. You should feel or hear a positive engagement. Gently pull on axles to verify they are locked in place.
11. 11

    Reinstall CV axles to hubs
    Insert the outer CV joint splines into the wheel hubs on both sides. Install new axle hub nuts finger tight. Do not fully torque at this time.
12. 12

    Refill rear differential
    Install new drain plug seal/gasket and reinstall drain plug. Using fluid pump and appropriate fill adapter, refill differential through fill hole with 2.0 quarts of 75W-90 GL-5 gear oil. Fill until fluid reaches the bottom of the fill hole and begins to seep out. Install new fill plug seal/gasket and reinstall fill plug.
13. 13

    Reconnect sensors and reinstall brake components
    Reconnect wheel speed sensor electrical connectors on both sides. Reinstall brake rotors if removed. Reinstall brake calipers with mounting bolts. Torque caliper bolts to specification per service manual.
14. 14

    Torque axle hub nuts and reinstall wheels
    Torque both rear axle hub nuts to specification per service manual. These require very high torque values. Reinstall rear wheels and torque lug nuts to specification in star pattern.

Reassembly

1. Reconnect 12V battery negative terminal
2. Lower vehicle to ground
3. Perform system initialization if required by vehicle computer
4. Torque all fasteners to specification (consult service manual for values not provided in this database)

Verification

• Start vehicle and verify no warning lights related to drivetrain or ABS system
• Test drive vehicle and verify smooth operation with no unusual noises from rear differential
• After test drive, raise vehicle and inspect for any gear oil leaks around axle seals, drain plug, and fill plug
• Verify wheel speed sensors are functioning properly with no ABS or traction control warning lights
• Recheck differential fluid level after test drive and top off if necessary

More procedures for this vehicle