Axle Shaft - Rear

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

Warnings

Tools required

Parts

• Rear axle shaft assembly × 1 — Use OEM specification
• Axle shaft seal × 1 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Use OEM specification
• Axle flange bolts × 1 — Use OEM specification
• Differential drain plug washer × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Use Rivian diagnostic tool to place vehicle in service mode if available
3. Disconnect 12V battery negative terminal and wait 5 minutes for system capacitors to discharge
4. Raise vehicle on lift or use appropriate jack and support on manufacturer-specified lift points
5. Remove rear wheel on the side where axle shaft is being replaced
6. Place wheel chocks on front wheels for additional safety
7. Verify high-voltage system indicator lights are off on dashboard

Procedure

1. 1

   Drain rear differential fluid
   Position drain pan under rear differential. Locate and remove the differential drain plug at the bottom of the rear differential housing. Allow all gear oil to drain completely (approximately 2 quarts). Inspect drained fluid for metal particles or contamination that might indicate additional wear issues.
2. 2

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and carefully suspend the caliper with mechanics wire or a bungee cord to avoid stressing the brake line. Remove the caliper bracket if necessary. Slide the brake rotor off the hub. If rotor is stuck, use light taps with a rubber mallet on the back side.
3. 3

   Disconnect wheel speed sensor
   Locate the wheel speed sensor connector near the wheel hub assembly. Press the release tab and disconnect the electrical connector. Carefully remove any retaining clips securing the sensor wire to the suspension components. Note the routing for reinstallation.
4. 4

   Remove axle shaft flange bolts
   Locate the CV joint or axle flange where the axle shaft connects to the differential output flange. Remove the bolts securing the axle shaft to the differential flange. There are typically 6-8 bolts in this location. Use a breaker bar if necessary as these bolts may be torqued to high specification. Support the outer end of the axle shaft to prevent it from dropping.
5. 5

   Remove hub retaining nut
   Remove the large axle hub nut at the center of the wheel hub. This nut is typically staked or uses a locking mechanism. You may need to have an assistant apply the brake pedal or use a pry bar against the wheel studs to prevent hub rotation while loosening. Use a breaker bar for initial loosening as this nut is torqued to very high specification.
6. 6

   Separate axle shaft from hub
   The axle shaft splines are press-fit into the wheel hub bearing. Use an axle puller or slide hammer with appropriate adapters to withdraw the axle shaft from the hub assembly. Apply steady, even pressure. If the shaft is severely seized, penetrating oil applied 15-30 minutes prior may help. Do not use excessive heat near the wheel bearing or electric motor components.
7. 7

   Remove axle shaft from differential
   Carefully pull the inner end of the axle shaft away from the differential housing. The shaft may have a snap ring or retaining clip at the differential side that must be released. Once separated, remove the entire axle shaft assembly from the vehicle. Keep the shaft level during removal to avoid damaging seals.
8. 8

   Inspect and replace differential seal
   With the axle shaft removed, inspect the differential seal for damage, wear, or leaking. Use a seal puller or screwdriver to carefully remove the old seal from the differential housing. Clean the seal bore thoroughly. Install the new seal using a seal driver or appropriate sized socket, driving it in squarely until fully seated. Lightly coat the seal lip with fresh gear oil.
9. 9

   Inspect hub bearing and differential output
   With the axle removed, inspect the wheel hub bearing for roughness, play, or noise by rotating the hub by hand. Check the differential output splines for damage or excessive wear. Inspect the CV joint boots (if equipped) on the new or reinstalled axle shaft for tears or damage. Replace the hub bearing if any issues are detected.
10. 10

    Install new or replacement axle shaft
    Align the new or replacement axle shaft with the differential output splines. Apply a thin coating of gear oil to the splines. Carefully insert the inner end of the axle shaft into the differential, ensuring it fully engages and seats. You should feel or hear a click when any retaining clip engages. Insert the outer end into the wheel hub, aligning the splines carefully.
11. 11

    Install hub retaining nut
    Thread the axle hub nut onto the axle shaft. Tighten the nut to manufacturer specification using a torque wrench. Apply appropriate locking mechanism (stake the nut or install locking device as per OEM design). Have an assistant apply the brake pedal or use a pry bar to prevent hub rotation during final torquing.
12. 12

    Install axle flange bolts
    Align the axle shaft flange with the differential output flange. Install new flange bolts if specified by manufacturer. Thread all bolts by hand first to ensure proper alignment. Tighten the bolts in a star or cross pattern to manufacturer specification using a torque wrench to ensure even loading.
13. 13

    Refill rear differential
    Reinstall the differential drain plug with a new washer. Tighten to manufacturer specification. Locate the differential fill plug (typically on the side of the housing). Remove the fill plug and add 75W-90 GL-5 gear oil until it reaches the bottom of the fill hole (approximately 2.0 quarts). The differential is full when oil begins to seep out of the fill hole. Reinstall fill plug and tighten.
14. 14

    Reinstall brake components and wheel
    Reinstall the brake rotor onto the hub. Mount the brake caliper and bracket, tightening bolts to specification. Reconnect the wheel speed sensor connector and secure the wire routing with all original clips. Install the wheel and hand-tighten lug nuts in a star pattern.

Reassembly

1. Lower vehicle until wheel is just touching the ground and torque lug nuts to specification in a star pattern
2. Fully lower vehicle and remove jack stands
3. Reconnect 12V battery negative terminal
4. Pump brake pedal several times until firm to ensure proper caliper piston seating
5. Check differential fill level once more after vehicle has been lowered and verify no leaks around drain and fill plugs

Verification

• Start vehicle and verify no warning lights related to ABS, traction control, or drivetrain appear on the dashboard
• Use diagnostic tool to verify wheel speed sensor is reading correctly and no fault codes are present
• Test drive vehicle in a safe area at low speed, checking for unusual noises, vibrations, or handling issues
• Perform a series of slow speed turns in both directions to verify proper axle operation and CV joint function
• After test drive, re-inspect differential area for any signs of leaking gear oil around the axle seal
• Recheck wheel lug nut torque after 50-100 miles of driving
• Monitor differential fluid level after first 100 miles and top off if necessary

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