CV Axle - Rear

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

Warnings

Tools required

Parts

• Rear CV axle assembly × 1 — Use OEM Rivian specification
• CV axle retaining clip (circlip) × 1 — Usually included with axle
• Hub axle nut × 1 — Replace if deformed - Use OEM specification
• Lower control arm ball joint castle nut × 1 — Use OEM specification
• Differential output seal × 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. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
3. Lift vehicle using appropriate lift points specified in Rivian service manual and secure on jack stands rated for vehicle weight
4. Remove rear wheel completely
5. Place high-voltage system in service mode following Rivian-specific procedures to disable traction control and ensure EDU is not powered
6. Position drain pan under rear differential area
7. Clean work area around CV axle, hub, and differential to prevent contamination

Procedure

1. 1

   Remove hub axle nut
   Using a breaker bar or impact wrench, remove the large axle nut in the center of the rear hub. This nut has high torque and may require significant force. Have an assistant apply brakes or use a hub holder tool to prevent rotation. Mark the nut orientation if it has a staked portion.
2. 2

   Disconnect brake caliper
   Remove the brake caliper mounting bolts and support the caliper with wire or a bungee cord - do not let it hang by the brake hose. The caliper does not need to be disconnected from the brake line. Remove the brake rotor to provide access to hub and suspension components.
3. 3

   Disconnect lower control arm
   Locate the lower control arm ball joint connection at the knuckle. Remove the castle nut and cotter pin (if equipped). Use a ball joint separator or pickle fork to separate the ball joint from the knuckle. Be careful not to damage the ball joint boot if reusing components.
4. 4

   Support knuckle assembly
   Use a jack or support stand to support the weight of the knuckle, hub, and attached suspension components. This prevents strain on remaining connections and provides control during axle removal.
5. 5

   Separate outer CV joint from hub
   With the axle nut removed, pull the knuckle assembly outward to separate the CV axle splines from the hub. If the axle is stuck, use a brass drift and hammer to tap the axle end through the hub bearing. Do not damage the axle threads or hub bearing during this process.
6. 6

   Remove inner CV joint from differential
   Position the drain pan directly under the differential output where the inner CV joint connects. Using a pry bar positioned against the differential housing and the inner CV joint body, carefully pry the axle from the differential. The retaining circlip will release with firm pressure. Be prepared for gear oil to drain immediately. If the axle will not release, use a CV axle puller or slide hammer with appropriate adapter.
7. 7

   Extract CV axle assembly
   Once both ends are disconnected, carefully maneuver the complete CV axle assembly out from the wheel well area. Note the routing path and any mounting brackets or clips that may have secured the axle shaft during operation.
8. 8

   Inspect and replace differential seal
   With the axle removed, inspect the differential output seal for damage or leakage. Use a seal puller or screwdriver to carefully remove the old seal. Clean the seal bore thoroughly with a wire brush and solvent. Install the new differential output seal using a seal driver or appropriately sized socket, ensuring it seats evenly and fully.
9. 9

   Prepare new CV axle
   Remove the new CV axle from packaging and inspect for shipping damage. Verify the new retaining circlip is properly seated in the groove on the inner CV joint. Apply a thin coating of gear oil to the differential splines and seal contact area. Verify the axle shaft length and spline count matches the original.
10. 10

    Install inner CV joint into differential
    Align the inner CV joint splines with the differential output shaft. Push the axle firmly into the differential until the retaining circlip audibly clicks into place. Verify engagement by attempting to pull the axle back out - it should not withdraw. If it pulls out, the circlip has not properly seated and must be reinstalled.
11. 11

    Install outer CV joint into hub
    Guide the outer CV joint splines through the hub bearing. Pull the knuckle assembly toward the axle while aligning splines. The axle should slide through smoothly. Do not force or damage the hub bearing or CV joint splines during installation.
12. 12

    Reconnect lower control arm
    Lower the knuckle assembly onto the lower control arm ball joint stud. Install the castle nut and tighten to specification (torque spec not available - use OEM specification). Install new cotter pin if equipped, or follow Rivian fastener retention method.
13. 13

    Install hub axle nut
    Thread the new (or inspected original) hub axle nut onto the axle shaft. Torque to manufacturer specification following Rivian service procedures. If the nut uses a staking method, stake the nut according to OEM procedure after final torque is achieved.
14. 14

    Refill rear differential
    Locate the rear differential fill plug. Using a transmission fluid pump, refill the rear differential with 2.0 quarts of 75W-90 GL-5 gear oil. Fill until fluid reaches the bottom of the fill plug opening. Reinstall the fill plug and torque to specification.

Reassembly

1. Reinstall brake rotor and ensure it seats properly on the hub
2. Reinstall brake caliper and torque mounting bolts to specification
3. Verify all fasteners are properly torqued and no tools or parts are left in the work area
4. Reinstall wheel and hand-tighten lug nuts in star pattern
5. Lower vehicle to ground and torque wheel lug nuts to Rivian specification in star pattern
6. Remove vehicle from high-voltage service mode following Rivian procedures

Verification

• Start vehicle and verify no warning lights related to drivetrain or ABS are present
• Test drive vehicle in safe area, checking for vibration, noise, or abnormal handling during acceleration and deceleration
• Verify no clicking or popping sounds from CV joint during tight turns in both directions
• Inspect differential fill plug and output seal area for leaks after test drive
• Re-check hub axle nut torque after 50-100 miles of driving
• Verify proper AWD operation by monitoring torque distribution display (if equipped) during acceleration

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