This procedure covers the removal and replacement of the front CV axle assembly on a 2024 Rivian EDV 500 electric delivery van with dual motor AWD drivetrain.

Warnings

Tools required

Parts

• Front CV axle assembly × 1 — Use OEM Rivian specification
• Axle seal (differential side) × 1 — Use OEM specification
• Axle nut (if not reusable) × 1 — Use OEM specification
• Lower control arm ball joint nut (if damaged) × 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. Place wheel chocks behind rear wheels
3. Open hood and locate 12V low-voltage battery in front compartment
4. Disconnect 12V negative battery terminal using battery disconnect tool
5. Wait minimum 5 minutes for high-voltage system capacitor discharge
6. Raise and secure vehicle on lift or jack stands at manufacturer-specified lift points
7. Remove front wheel on side being serviced
8. Place drain pan under front differential on the side being serviced

Procedure

1. 1

   Remove axle nut
   With vehicle still on ground (if possible) or with helper applying brake, use breaker bar to loosen and remove the large center axle nut from the hub. This nut is very tight and may require significant force. If axle spins, have assistant apply brake pedal or reinstall wheel partially with lug nuts to hold hub stationary.
2. 2

   Disconnect wheel speed sensor
   Locate the ABS wheel speed sensor connector near the strut assembly. Press the release tab and carefully disconnect the electrical connector. Unclip any retaining clips securing the sensor wire to the strut or control arm.
3. 3

   Separate lower ball joint
   Remove the nut securing the lower control arm ball joint to the steering knuckle. Use a ball joint separator tool or pickle fork to separate the ball joint taper from the knuckle. Apply penetrating oil if joint is seized. Note: This may damage the ball joint boot.
4. 4

   Support knuckle assembly
   Use a hydraulic jack or support stand to support the weight of the knuckle, brake caliper, and hub assembly. This prevents strain on the brake hose and allows controlled movement of the knuckle during axle removal.
5. 5

   Push axle out of hub
   With the ball joint separated and knuckle supported, push the outer CV joint stub shaft out of the wheel hub splines. You may need to use a brass drift and hammer to tap the end of the axle shaft, or use a hub puller if the splines are corroded. Pull the knuckle assembly outward to clear the axle from the hub.
6. 6

   Mark differential position
   Before removing the inner CV joint from the differential, note the installed depth and orientation. This helps with installation of the new axle to ensure proper engagement with the differential side gears.
7. 7

   Remove axle from differential
   Using a pry bar positioned against the differential housing and the inner CV joint housing, carefully pry the axle out of the differential. Apply steady force to release the circlip retaining the axle. Alternatively, use a slide hammer attached to the inner CV joint. Expect differential fluid to drain when axle is removed. Catch fluid in drain pan.
8. 8

   Remove complete axle assembly
   Carefully maneuver the complete CV axle assembly out from under the vehicle, threading it past suspension components, brake lines, and the motor housing. The axle may need to be angled and rotated to clear all obstructions.
9. 9

   Inspect and replace differential seal
   With axle removed, inspect the differential seal for damage or leaking. Use a seal removal tool or pick to carefully pry out the old seal. Clean the seal bore with a wire brush and solvent. Install new seal using a seal driver or large socket, ensuring it seats fully and squarely in the bore.
10. 10

    Prepare new axle for installation
    Remove the new CV axle from packaging and inspect for shipping damage. Ensure the circlip on the inner CV joint is properly seated in its groove. Apply a thin coat of gear oil to the seal contact surface on the inner CV joint shaft.
11. 11

    Install axle into differential
    Align the inner CV joint splines with the differential side gear. Push the axle firmly into the differential until the circlip engages with an audible click. Pull back on the axle to verify it is locked in place by the circlip. The axle should not pull out of the differential.
12. 12

    Install axle into hub
    Guide the outer CV joint stub shaft through the wheel hub splines. You may need to rotate the axle slightly to align the splines. Pull the knuckle assembly inward and push the axle shaft fully through the hub until the threads protrude for the axle nut.
13. 13

    Reconnect lower ball joint
    Raise or lower the lower control arm as needed to align the ball joint stud with the hole in the steering knuckle. Insert the ball joint stud and install a new nut (or reuse if in good condition). Tighten the nut to specification per Rivian service documentation.
14. 14

    Install and torque axle nut
    Install the axle nut onto the stub shaft threads. Initially snug by hand, then use a torque wrench to tighten to specification per Rivian service documentation. Have an assistant apply the brake or use wheel lug nuts to prevent rotation during final torque. Stake or install cotter pin if applicable to nut design.
15. 15

    Refill differential and reconnect sensor
    Add 75W-90 GL-5 gear oil to the front differential through the fill plug until fluid reaches the bottom of the fill hole (approximately 1.5 quarts total capacity). Reinstall fill plug. Reconnect the wheel speed sensor electrical connector and secure the wire with retaining clips.

Reassembly

1. Reinstall the front wheel and torque lug nuts to specification in a star pattern
2. Lower the vehicle to the ground
3. Reconnect the 12V negative battery terminal
4. Perform a final check of all fasteners and connections
5. Check front differential fluid level after test drive and top off if necessary

Verification

• Start the vehicle and verify no warning lights appear on the instrument cluster related to ABS or traction control
• Perform a slow-speed test drive and verify no clicking, popping, or vibration from the front axle
• Turn the steering wheel full lock in both directions while driving slowly to verify CV joint operation
• Inspect underneath the vehicle for any differential fluid leaks around the new seal
• Verify proper operation of ABS system by performing a controlled stop from moderate speed on safe surface
• Re-torque the axle nut after 50-100 miles of driving as a precautionary measure

More procedures for this vehicle