This procedure covers the removal and replacement of the battery junction box on a 2024 Rivian EDV 500, which manages high-voltage power distribution between the battery pack and drive motors.

Warnings

Tools required

Parts

• Battery junction box assembly × 1 — Use OEM specification
• HV connector seals × 4 — Use OEM specification
• Junction box mounting gasket × 1 — Use OEM specification
• HV interlock connector × 1 — Use OEM specification
• Cable tie/retention clips × 8 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off for minimum 30 minutes to allow systems to power down
3. Connect Rivian service software to vehicle diagnostic port
4. Document any stored fault codes related to HV system
5. Disconnect 12V auxiliary battery negative terminal and wait 5 minutes
6. Remove front underbody access panels to expose battery pack area
7. Put on high-voltage insulated gloves and verify glove integrity
8. Place HV warning tags on steering wheel and charge port

Procedure

1. 1

   Disable high-voltage system
   Using Rivian service software, initiate HV system shutdown procedure. Navigate to 'Service Mode' and select 'HV Isolation'. Verify on-screen confirmation that all contactors are open and system is isolated. Record confirmation code displayed on screen.
2. 2

   Remove HV service disconnect
   Access the high-voltage service disconnect located under the center console area. Remove the protective cover by releasing two quarter-turn fasteners. Pull the orange service disconnect handle straight up to remove. Store in a secure location away from vehicle. Verify service disconnect indicator light on dash cluster is illuminated.
3. 3

   Wait for capacitor discharge and verify isolation
   Wait minimum 15 minutes for high-voltage system capacitors to fully discharge. After waiting period, use high-voltage multimeter to verify zero voltage at test points on junction box cover. Measure between positive and negative bus bars, then from each to chassis ground. All readings must be below 5V DC before proceeding.
4. 4

   Remove junction box protective cover
   Locate the battery junction box on the underside of the vehicle, forward of the battery pack. Remove eight perimeter bolts securing the aluminum protective cover. Carefully lower the cover, being mindful of any attached ground straps. Disconnect ground straps if present and set cover aside.
5. 5

   Disconnect HV interlock circuit
   Locate the orange HV interlock connector on the side of the junction box. Press the locking tab and carefully disconnect the interlock connector. Inspect connector pins for damage or corrosion. This disables the HV interlock safety circuit.
6. 6

   Disconnect low-voltage control connectors
   Identify three low-voltage control harness connectors on the junction box. These are typically gray or black multi-pin connectors. Press each connector's locking tab and carefully pull straight out to disconnect. Label each connector with its position (C1, C2, C3) using masking tape for reinstallation reference.
7. 7

   Remove HV positive cable connection
   Locate the large orange high-voltage positive cable connection on the junction box. Remove the protective boot by pulling back on the retention collar. Remove the two or three bolts securing the cable lug to the positive bus bar. Use cable spreader tool if needed to relieve tension. Carefully move cable aside and cover exposed terminal with insulating cap.
8. 8

   Remove HV negative cable connection
   Locate the large orange or blue high-voltage negative cable connection. Remove protective boot and securing bolts in same manner as positive cable. Use cable spreader tool to relieve any tension. Move cable aside and cover exposed terminal with insulating cap. Ensure cables are secured away from work area.
9. 9

   Disconnect motor drive cables
   Identify the motor drive cables connecting to the junction box (typically two cables for dual motor configuration). Remove protective boots and securing hardware for each motor cable connection. Document which cable connects to front motor and which to rear motor. Carefully disconnect and secure each cable with insulating caps.
10. 10

    Remove junction box mounting hardware
    Locate the four to six mounting bolts securing the junction box to the battery pack structure. These are typically 10mm or 13mm head bolts. Support the junction box weight before removing final bolts. Remove all mounting bolts and carefully note location of any spacers or alignment pins.
11. 11

    Remove junction box assembly
    With all connections and mounting hardware removed, carefully lower the junction box assembly. The unit weighs approximately 35 lbs, so use proper lifting technique or have an assistant help. Inspect the mounting gasket and sealing surfaces for damage. Remove and discard old gasket material from battery pack mounting surface.
12. 12

    Prepare new junction box
    Unpack new junction box and verify part number matches vehicle specification. Install new mounting gasket onto junction box. Apply thin layer of dielectric grease to all HV cable connection points on the new junction box. Inspect all connector sockets for foreign material or shipping plugs that need removal.
13. 13

    Install new junction box assembly
    Carefully lift new junction box into position, aligning mounting holes with battery pack structure. Ensure gasket remains properly seated. Install mounting bolts finger-tight initially to allow for positioning adjustment. Verify alignment, then torque mounting bolts in star pattern. Follow torque specifications provided in service manual for your specific model if available.
14. 14

    Reconnect HV cables
    Remove insulating caps from HV cables. Clean cable lug contact surfaces with wire brush if needed. Reconnect motor drive cables first, followed by negative cable, then positive cable. Install new connector seals on each connection. Torque all HV cable connections per service manual specifications. Apply dielectric grease to exposed connection areas before installing protective boots.
15. 15

    Reconnect control circuits and verify installation
    Reconnect all low-voltage control harness connectors in their documented positions, ensuring positive click engagement. Reconnect HV interlock connector. Reinstall protective cover and ground straps. Torque cover bolts evenly. Perform visual inspection of all connections before proceeding to system verification.

Reassembly

1. Reinstall all underbody access panels and verify all fasteners are secure
2. Remove HV warning tags from vehicle
3. Reinstall HV service disconnect by pushing orange handle down until it clicks into place
4. Reconnect 12V auxiliary battery negative terminal
5. Connect Rivian service software and clear any service mode flags

Verification

• Using Rivian service software, perform HV system integrity check to verify all connections are properly seated
• Check for any new fault codes related to battery junction box or HV system
• Perform insulation resistance test using service software - all readings should be above specification
• Exit service mode and allow vehicle to power up normally
• Verify battery junction box cooling fan operates when commanded through service software
• Observe instrument cluster for any HV system warning lights or messages
• Perform test drive to verify normal operation of both drive motors
• Recheck all torque values on HV connections and mounting hardware
• Document repair in vehicle service history with junction box serial number

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