Differential Service

Service both front and rear differentials on the Rivian EDV 500 dual motor AWD system by draining old gear oil, inspecting components, and refilling with fresh 75W-90 GL-5 gear oil.

Warnings

Tools required

Parts

• Front differential drain plug washer × 1 — Use OEM specification
• Front differential fill plug washer × 1 — Use OEM specification
• Rear differential drain plug washer × 1 — Use OEM specification
• Rear differential fill plug washer × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 4 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Raise vehicle on lift or secure with jack stands at manufacturer-specified lift points
4. Allow differentials to cool to safe handling temperature if vehicle was recently operated
5. Remove rear skid plate or undertray panels if equipped to access differential drain/fill plugs
6. Clean area around differential housings to prevent contamination during service

Procedure

1. 1

   Locate front differential service plugs
   Identify the front differential drain plug (lower position) and fill plug (upper position) on the front drive unit housing. Clean the surrounding area with a wire brush or shop towels to remove dirt and debris.
2. 2

   Remove front differential fill plug first
   Using the appropriate tool (typically hex key or Torx bit), carefully loosen and remove the front differential fill plug. This ensures you can refill the unit after draining. If the fill plug is seized, do not proceed with draining until it can be removed.
   ⚠Always remove fill plug before drain plug to ensure you can refill the differential after draining.
3. 3

   Drain front differential
   Position drain pan under the front differential drain plug. Remove the drain plug and allow gear oil to drain completely. This may take 5-10 minutes. Inspect drained fluid for metal particles, debris, or unusual discoloration which may indicate internal wear.
4. 4

   Reinstall front differential drain plug
   Clean the drain plug and magnetic tip (if equipped) with shop towels. Install a new crush washer on the drain plug. Thread drain plug into housing by hand first, then tighten to specification. Note: Torque specification not available in database - consult factory service manual for proper torque value.
5. 5

   Refill front differential
   Using a fluid transfer pump or squeeze bottle, add 1.5 quarts of 75W-90 GL-5 gear oil through the fill hole. Fill until oil begins to drip from the fill hole opening, indicating proper level. Vehicle must be level during this procedure.
6. 6

   Install front differential fill plug
   Clean the fill plug and install a new crush washer. Thread plug into housing by hand, then tighten to specification. Note: Torque specification not available in database - consult factory service manual for proper torque value.
7. 7

   Locate rear differential service plugs
   Move to the rear drive unit and identify the rear differential drain plug (lower position) and fill plug (upper position) on the rear drive unit housing. Clean the surrounding area thoroughly to prevent contamination.
8. 8

   Remove rear differential fill plug
   Using the appropriate tool, carefully loosen and remove the rear differential fill plug before proceeding with draining. Verify the fill plug can be removed and reinstalled before draining the unit.
   ⚠Always remove fill plug before drain plug to ensure you can refill the differential after draining.
9. 9

   Drain rear differential
   Position drain pan under the rear differential drain plug. Remove the drain plug and allow gear oil to drain completely, approximately 5-10 minutes. Inspect drained fluid for metal particles, water contamination, or burnt odor indicating potential issues.
10. 10

    Reinstall rear differential drain plug
    Clean the drain plug and magnetic tip (if equipped) thoroughly. Install a new crush washer on the drain plug. Thread drain plug into housing by hand to prevent cross-threading, then tighten to specification. Note: Torque specification not available in database - consult factory service manual.
11. 11

    Refill rear differential
    Using a fluid transfer pump or squeeze bottle, add 2.0 quarts of 75W-90 GL-5 gear oil through the rear fill hole. Fill until oil begins to drip from the fill hole opening. Ensure vehicle is level to achieve proper fill level.
12. 12

    Install rear differential fill plug
    Clean the fill plug and install a new crush washer. Thread plug into housing by hand first, then tighten to specification. Note: Torque specification not available in database - consult factory service manual for proper torque value.
13. 13

    Clean and inspect for leaks
    Wipe down both differential housings to remove any spilled gear oil. Inspect all plug areas for signs of leakage. Reinstall any skid plates or undertray panels that were removed for access.

Reassembly

1. Reinstall all undertray panels and skid plates removed during service
2. Verify all drain and fill plugs are properly tightened
3. Lower vehicle to ground and remove jack stands
4. Dispose of used gear oil at appropriate recycling facility

Verification

• Start vehicle and verify no warning lights appear on the instrument cluster
• Test drive vehicle in normal conditions for 5-10 minutes, exercising both acceleration and deceleration
• After test drive, raise vehicle and inspect both differentials for any signs of leakage around drain and fill plugs
• Check for unusual noises from either differential during operation which could indicate improper fill level
• Verify smooth operation during turns and acceleration with no binding or unusual vibration

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