This procedure covers the replacement of the front axle seal on a 2024 Rivian EDV 500, including removal of the front driveshaft, halfshaft, and differential seal replacement.

Warnings

Tools required

Parts

• Front axle seal × 1 — Use OEM Rivian specification
• Front halfshaft nut × 1 — Use OEM Rivian specification - one-time use
• Front differential drain plug washer × 1 — Use OEM specification
• Front differential fill plug washer × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect 12V battery negative terminal and wait 2 minutes for system capacitors to discharge
3. Verify high-voltage system is de-energized following manufacturer lockout/tagout procedures
4. Raise vehicle on lift or secure on jack stands at manufacturer-specified lift points
5. Remove front wheel on the side requiring seal replacement
6. Place drain pan under front differential
7. Clean area around differential drain and fill plugs to prevent contamination

Procedure

1. 1

   Remove axle nut and prepare halfshaft
   With vehicle on ground and brakes applied, or with assistant holding brake pedal, loosen the front axle nut using a breaker bar. Once loosened, raise vehicle and remove the axle nut completely. Keep the nut for reference as it is single-use and must be replaced.
2. 2

   Drain front differential fluid
   Position drain pan beneath the front differential. Remove the drain plug from the bottom of the differential housing and allow all fluid to drain completely. Inspect drained fluid for metal particles or contamination. Remove and discard the drain plug washer.
3. 3

   Disconnect lower control arm or ball joint
   Remove the fasteners securing the lower ball joint to the steering knuckle. Use a ball joint separator tool if needed to separate the joint. Support the lower control arm to prevent damage to suspension components.
4. 4

   Remove halfshaft from hub
   Pull the steering knuckle outward while pushing the halfshaft out of the hub assembly. If the halfshaft is stuck in the hub, use a soft mallet to tap it from behind the hub or use a puller tool. Be careful not to damage CV joint boots during removal.
5. 5

   Remove halfshaft from differential
   Using a pry bar positioned against the differential housing, carefully pry the inner CV joint from the differential. Apply steady pressure to release the circlip retaining the halfshaft. Once released, remove the halfshaft completely from the vehicle and set aside on a clean surface.
6. 6

   Extract old axle seal
   Using a seal puller or a hooked seal removal tool, carefully extract the old axle seal from the differential housing. Work carefully to avoid damaging the seal bore surface. Clean the seal bore thoroughly with a clean rag, inspecting for any scoring or damage that would prevent proper seal seating.
7. 7

   Install new axle seal
   Lightly lubricate the outer diameter of the new seal with fresh 75W-90 gear oil. Position the seal squarely in the bore with the seal lip facing inward toward the differential. Using a seal driver of the appropriate size, drive the seal evenly into the housing until it seats flush with the housing surface or reaches the factory specified depth. Ensure the seal is not cocked or damaged during installation.
8. 8

   Prepare halfshaft for installation
   Inspect the halfshaft splines and circlip for damage or wear. Replace the circlip if it appears deformed or weakened. Apply a thin coating of fresh gear oil to the seal surface area of the halfshaft and to the splines that will enter the differential.
9. 9

   Install halfshaft into differential
   Align the halfshaft with the differential opening and carefully push it in until the circlip engages with an audible click. Pull outward on the halfshaft to verify it is properly retained by the circlip and will not pull out of the differential.
10. 10

    Reinstall halfshaft to hub and suspension
    Guide the outer end of the halfshaft through the hub bearing. Reconnect the lower ball joint to the steering knuckle and install fasteners finger-tight. Install a new axle nut on the halfshaft threads and tighten finger-tight to hold components in position.
11. 11

    Refill front differential
    Install a new washer on the drain plug and reinstall the drain plug. Remove the fill plug from the side of the differential. Using a fluid transfer pump, add 1.5 quarts of 75W-90 GL-5 gear oil through the fill port until fluid reaches the bottom of the fill plug opening. Install a new washer on the fill plug and reinstall the fill plug.
12. 12

    Torque all fasteners
    Following proper torque sequence, torque all suspension and steering fasteners to manufacturer specifications. Note: Specific torque values are not available in the database - consult Rivian service information for proper specifications. With vehicle lowered to ground or brakes applied, torque the new axle nut to specification.

Reassembly

1. Reinstall front wheel and torque lug nuts to specification in a star pattern
2. Lower vehicle to ground
3. Reconnect 12V battery negative terminal
4. Perform a final visual inspection of all work areas to ensure no tools or parts were left behind
5. Reset any fault codes related to battery disconnect using appropriate diagnostic equipment

Verification

• Start vehicle and verify all systems operate normally with no warning lights
• Test drive vehicle at low speed and verify no vibration or unusual noises from the front axle area
• After test drive, raise vehicle and inspect the new axle seal for any signs of leakage
• Check front differential fluid level after test drive and top off if necessary
• Verify proper operation of AWD system if equipped with selectable modes
• Recheck all fastener torque values after initial test drive

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